Buell X1 2002 Service Manual page 92

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CLEANING AND INSPECTION
11 1
WARNING
Clean brake system components using denatured alco-
hol. Do not use mineral-base cleaning solvents, such as
gasoline or paint thinner. Use of mineral-base solvents
causes deterioration of rubber parts that continues after
assembly. This may result in improper brake operation
which could result in death or serious injury.
1. Clean all parts with denatured alcohol or D.O.T. 4
BRAKE FLUID. Do not contaminate with mineral oil or
other solvents. Wipe dry with a clean, lint free cloth. Blow
out drilled passages and bore with a clean air supply. Do
not use a wire or similar instrument to clean drilled pas-
sages.
2. Carefully inspect all components. Replace any parts that
appear damaged or worn. Do not hone caliper piston
bore.
11 1
WARNING
Always replace brake pads in complete sets for correct
brake operation. Never replace just one brake pad. Fail-
ure to install brake pads as a set could result in death or
serious injury.
3. Inspect brake rotor and pads. See
AND ROTORS.
ASSEMBLY
1. See Figure 2-32. Install pistons and O-rings.
a. Apply a light coat of D.O.T. 4 BRAKE FLUID to O-
rings, pistons and caliper piston bores.
b. Install two new O-rings (6) in grooves of each piston
bore.
c. Install pistons (5) in each piston bore.
2. Install two new O-rings (3) between caliper halves.
3. Attach caliper halves together with four screws (7) (met-
ric). Tighten to 14.5-18 ft-lbs (20-24 Nm).
4. Install a new bleeder valve (4) (metric) if necessary.
Tighten to 3-5 ft-lbs (4-7 Nm).
INSTALLATION
1. Fit front brake caliper on rotor.
a. Check rotor attachment to carrier. Inspect all six T-
40 TORX screws.
b. Make sure rotor is centered on carrier. Use two
clamps on rotor and carrier to reduce free play and
center rotor.
c. Slide caliper over front brake rotor without brake
pads installed.
2. See Figure 2-29. Apply LOCTITE THREADLOCKER 272
(red) to both caliper mounting screws (5). Install and
tighten screws to 22-25 ft-lbs (30-34 Nm).
2-24
WARNING
WARNING
1.8 BRAKE PADS
6495
Figure 2-31. Removing Pistons
6482
1
2
3
3
1. Outside Caliper Half
2. Inside Caliper Half
3. O-ring (2)
4. Bleeder Valve (metric)
5. Piston (3 sizes, 2 each)
6. Piston O-rings (3 sizes, 2 each)
7. Screws (4) (metric)
Figure 2-32. Caliper O-Rings and Pistons
3. Install brake pads.
a. See Figure 2-33. Insert brake pads from behind.
b. See Figure 2-30. Install pad spring (2) with opening
at top as shown.
c. Install pad hanger pin (1) (metric). Tighten to 11-
14.5 ft-lbs (15-20 Nm).
d. See Figure 2-29. Install pin plug (4). Tighten to 1.5-
2.1 ft-lbs (2-3 Nm).
11 1
WARNING
Use only new black banjo washers (See Parts Catalog for
Part No.) with D.O.T. 4 brake fluid. Earlier silver banjo
washers are not compatible with D.O.T. 4 fluid and will
not seal properly over time. Failure to comply may
adversely affect braking ability and lead to brake failure
which could result in death or serious injury.
4
6
7
5
WARNING
2002 Buell X1: Chassis