buell s1 lightning '97 Manual

NOTE

Step 1 (draining fluid) is not required for caliper removal.
Drain brake fluid only when disassembling caliper.

1.

See 

Open bleeder nipple cap on rear cali-

per. Install end of a length of plastic tubing over caliper
bleeder valve (2), while placing free end in a suitable
container. Open bleeder valve (metric) about 1/2-turn.
Pump brake pedal to drain brake fluid.

2.

Remove both caliper mounting screws (11) (metric) and
washers (10) to free caliper from caliper mount.

3.

Pump brake pedal until piston reaches its full travel.
Remove banjo bolt (1) (metric) and two gaskets (3) to
disconnect brake line from caliper. Discard gaskets.

4.

Remove slave pad from rear pad bracket (9).

5.

Remove rear pad bracket and dust boots (12, 13) from
rear caliper assembly (4).

6.

Remove master brake pad (7) from piston (6).

NOTE

Do not remove piston from caliper unless there are signs of
hydraulic fluid leakage or piston is not operating properly. If
piston must be removed, proceed to Step 7. 

1

1

7.

Hold caliper with piston facing downward. Place a clean
shop towel under piston. Apply low air pressure to
hydraulic brake line inlet hole until piston is forced out
caliper bore. If piston is tight in bore, tap lightly around
caliper while applying air pressure.

8.

Remove and discard O-ring (5) from groove within piston
bore. 

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