Front Brake Caliper - Buell 2002 X1 Handbook

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FRONT BRAKE CALIPER

REMOVAL
NOTE
Steps 1 and 2 are not required for detaching caliper from
rotor. Drain fluid only when disassembling caliper.
1. Drain and discard brake fluid.
CAUTION
Damaged banjo bolt seating surfaces will leak when
reassembled. Prevent damage to seating surfaces by
carefully removing brake line components.
2. See Figure 2-29. Remove banjo bolt (2) (metric) and two
banjo washers (3) to disconnect brake line (1) from cali-
per. Discard banjo washers.
3. Remove brake pads.
a. Remove pin plug (4).
b. See Figure 2-30. Remove pad hanger pin (1) (met-
ric).
c. Remove pad spring (2).
d. Remove brake pads from caliper.
4. See Figure 2-29. Detach caliper from mounts.
a. Remove both mounting screws (5) while supporting
caliper above brake rotor.
b. Slowly remove caliper by tilting away from wheel
and then pulling away from rotor.
DISASSEMBLY
1. See Figure 2-30. Remove four screws (3) (metric) to
separate caliper halves.
2. Remove two O-rings from between caliper halves and
discard.
3. See Figure 2-31. Use BRAKE CALIPER PISTON
REMOVER (Part No. B-42887) without adaptor to pull
the six pistons from caliper bores.
4. See Figure 2-32. Pry O-rings (6) out of their respective
grooves on each side of caliper. Discard O-rings.
5. Check bleeder valve (4) (metric). Remove and replace if
damaged.
2002 Buell X1: Chassis
7994
1
2
3
4
1. Brake Line
2. Banjo Bolt (metric)
3. Banjo Washers (2)
4. Pin Plug
5. Mounting Screws (2)
Figure 2-29. Front Brake Caliper Mounts
7046
2
1. Pad Hanger Pin (metric)
2. Pad Spring
3. Screws (4) (metric)
Figure 2-30. Pad Spring (Typical)
2.11
5
3
1
3
2-23