Brake Pad Replacement - Buell Ulysses 2006 Service Manual

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BRAKE PAD REPLACEMENT

Front Pad Removal
1. See Figure 1-19. Loosen pin hanger under pin hanger
plug (3) but do not remove.
2. Rotate wheel so that caliper is centered between rotor
mounting fasteners (1).
3. Remove lower caliper mounting fastener (4) that secures
caliper to fork lower.
4. Loosen but do not remove upper caliper mounting fas-
tener (2) that secures caliper to fork lower.
5. Remove pin hanger under pin hanger plug (3).
6. Rotate caliper counterclockwise to allow access to outer
pad.
7. Remove outer pad from right side.
8. Remove inner pad from left side by pulling rearward,
rotating pad 90 degrees and pulling through wheel open-
ing.
Front Pad Installation
1. Remove front master cylinder reservoir cover.
NOTE
As the pistons are pushed back into the caliper, fluid level
may rise more than 1/8 inch (3.2 mm) and overflow the reser-
voir. Watch the fluid level as the pistons are retracted and
remove fluid from the reservoir if necessary.
2. Push pistons in with suitable tool such as a clean paint
scraper until fully seated in bores. Be careful not to dam-
age rotor.
3. Install new inner pad from left side of motorcycle.
4. Install new outer pad from right side of motorcycle.
5. See Figure 1-19. Install pin under pin hanger plug (3)
making sure it engages hole on both pads and spring
clip.
6. Rotate caliper clockwise to align mounting fastener hole.
7. See Figure 1-19. Install lower caliper mounting
fastener (4).
8. Apply LOCTITE 272 and tighten both caliper mounting
fasteners (2, 4) to 35-37 ft-lbs (48-50 Nm).
9. Tighten pin under (3) to 11-14 ft-lbs (15-19 Nm).
10. Install pin plug (3). Tighten plug to 18-25 in-lbs (2-
3 Nm).
11. Check fluid level and reinstall front master cylinder reser-
voir cover and tighten screws to 9-13 in-lbs (1-1.5 Nm).
NOTE
Avoid making hard stops for the first 100 miles (160 km) to
allow new brake pads to "wear in" properly with the rotor.
Rear Pad Removal
1. See Figure 1-22. Remove rear caliper pin plug (4) and
loosen pin (3).
2. Remove two mounting fasteners (1) securing brake cali-
per and carrier assembly to swingarm.
3. Lift caliper and carrier assembly up and off of rotor.
4. Remove pin hanger (3).
5. Remove inner and outer pads, being careful not to dis-
lodge pad spring.
8346
1. Rotor mounting fastener (6)
2. Upper caliper mounting fastener (behind fender)
3. Front caliper pin plug
4. Lower caliper mounting fastener
Figure 1-19. Front Brake Caliper
6487
2
1
1. Rear caliper mounting fasteners
2. Retainer
3. Rear caliper pin plug
4. Rear caliper hanger pin
Figure 1-20. Rear Brake Caliper
2006 Buell Ulysses: Maintenance
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