Warning Warning; Serious Injury. (00317A) - Buell P3 Service Manual

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CLEANING AND INSPECTION
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WARNING
Use denatured alcohol to clean brake system compo-
nents. Do not use mineral-based solvents (such as gaso-
line or paint thinner), which will deteriorate rubber parts
even after assembly. Deterioration of these components
can cause brake failure, which could result in death or
serious injury. (00291a)
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.
3. Inspect brake rotor.
a. Measure rotor thickness. Replace if minimum thick-
ness is less than 0.180 in. (4.5 mm).
b. Check rotor surface. Replace if warped or badly
scored.
11 1
WARNING
Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation
could result in death or serious injury. (00111a)
4. Inspect brake pads for damage or excessive wear.
Replace both pads as a set if the friction material of
either pad is worn to 0.040 in. (1.0 mm) or less.
WARNING
WARNING
ASSEMBLY
1. See Figure 2-57. Place clip (1) inside caliper body as
shown.
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1. Clip
2. Pin plug and pad hanger (metric)
3. Brake pads (2)
Figure 2-57. Brake Pads
NOTE
To ensure proper brake pad-to-brake rotor clearance when
the caliper is installed, piston must be pressed all the way into
the bore whenever new brake pads are used.
2. Install pistons and o-rings.
a. Apply a light coat of D.O.T. 4 BRAKE FLUID to o-
rings, piston and caliper piston bore.
b. Place two new o-rings inside grooves of piston bore.
c. Install piston inside caliper body.
3. See Figure 2-57. Install brake pads (3) using pad hanger
and pin plug (2).
a. Install pad hanger pin (metric). Tighten to 132-180
in-lbs (15-20 Nm).
b. Install pin plug. Tighten to 18-25 in-lbs (2-3 Nm).
4. Install a new bleeder valve (metric) if necessary. Tighten
to 36-60 in-lbs (4-7 Nm).
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2007 Buell P3: Chassis 2-39