buell s1 lightning '97 Manual
2-21
1
WARNING
When using air pressure to remove pistons from caliper,
pistons may be ejected with considerable force. Wear
safety glasses, heavy gloves and hold caliper with heavy
towel to prevent personal injury.
pistons may be ejected with considerable force. Wear
safety glasses, heavy gloves and hold caliper with heavy
towel to prevent personal injury.
1
CAUTION
Exercise care to avoid dropping piston on hard surface.
Any damage requires piston replacement.
Any damage requires piston replacement.
9.
See
Use
BRAKE CALIPER PISTON
REMOVER (Part No. B-42079)
to remove caliper pistons.
10. See
Pry O-rings (9) out of their respective
grooves on each side of caliper. Discard O-rings.
CLEANING, INSPECTION AND
REPAIR
REPAIR
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 could result in improper and unsafe brake
operation which may cause personal injury.
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 could result in improper and unsafe brake
operation which may cause personal injury.
1.
Thoroughly clean brake system components using dena-
tured alcohol. Blow dry using compressed air. Carefully
inspect all components. Replace any parts that appear
damaged or worn. Do not hone caliper piston bore.
tured alcohol. Blow dry using compressed air. Carefully
inspect all components. Replace any parts that appear
damaged or worn. Do not hone caliper piston bore.
2.
Inspect brake rotor. Replace if warped or badly scored.
Measure rotor thickness for excessive wear. Replace
rotors less than 0.17 in. (4.3 mm) thick.
Measure rotor thickness for excessive wear. Replace
rotors less than 0.17 in. (4.3 mm) thick.
1
WARNING
Always replace brake pads in complete sets for correct
and safe brake operation. Never replace just one brake
pad. Failure to install brake pads as a set may cause per-
sonal injury.
and safe brake operation. Never replace just one brake
pad. Failure to install brake pads as a set may cause per-
sonal injury.
3.
Inspect brake pads for damage or wear. Replace both
pads as a set if the friction material of either pad is worn
to 1/16 in. (1.6 mm) or less.
pads as a set if the friction material of either pad is worn
to 1/16 in. (1.6 mm) or less.
ASSEMBLY
1.
See
Install new O-rings (11) in groove of
each caliper half (7, 12). Install new O-rings (9) in groove
of piston bores.
of piston bores.
2.
Install pistons (10) in each caliper piston bore.
3.
Tighten caliper halves together with four screws (13, 14).
Smallest screw (13) is placed on top next to bleeder
valve (8). Tighten screws to 26-28 ft-lbs (35.2-38.0 Nm).
Smallest screw (13) is placed on top next to bleeder
valve (8). Tighten screws to 26-28 ft-lbs (35.2-38.0 Nm).
INSTALLATION
1.
Fit caliper on front brake rotor without brake pads.
2.
See
Tighten both caliper mounting bolts (4)
to 30-33 ft-lbs (40.7-44.7 Nm).
3.
Insert brake pads (15) from top.
4.
Install center caliper bolt (3) and spacer (16). Tighten
center caliper bolt to 11-13 ft-lbs (14.9-17.6 Nm).
center caliper bolt to 11-13 ft-lbs (14.9-17.6 Nm).
5.
Install two support pins (1) and new cotter pins (2).
6.
Connect brake line to caliper using new gaskets. Tighten
banjo bolt (5) to 16-20 ft-lbs (21.7-27.1 Nm).
banjo bolt (5) to 16-20 ft-lbs (21.7-27.1 Nm).
7.
With the master cylinder in a level position, verify that the
brake fluid level is 1/8 in. (3.2 mm) from molded boss
inside reservoir. Add D.O.T. 5 SILICONE HYDRAULIC
BRAKE FLUID if necessary.
brake fluid level is 1/8 in. (3.2 mm) from molded boss
inside reservoir. Add D.O.T. 5 SILICONE HYDRAULIC
BRAKE FLUID if necessary.
1
WARNING
A plugged or covered relief port can cause brake drag or
lockup, which may result in loss of vehicle control and
possible personal injury.
lockup, which may result in loss of vehicle control and
possible personal injury.
8.
Verify proper operation of the master cylinder relief port.
Actuate the brake lever with the reservoir cover removed.
A slight spurt of fluid will break the surface if all internal
components are working properly.
Actuate the brake lever with the reservoir cover removed.
A slight spurt of fluid will break the surface if all internal
components are working properly.
9.
Install cover gasket, cover and screws. Tighten screws to
9-13 in-lbs (1.0-1.5 Nm).
9-13 in-lbs (1.0-1.5 Nm).
10. Depress front brake lever several times to set brake pads
to proper operating position within caliper. Bleed brake
system. See
system. See
BRAKES
in Section 1.
11. Test brake lamp operation with the brake hand lever
applied and the ignition/headlamp switch turned to IGN.
NOTE
To allow new brake pads to “wear in” properly with the brake
rotor, avoid making hard stops for the first 100 miles (160 km).
rotor, avoid making hard stops for the first 100 miles (160 km).
Figure 2-21. Removing Brake Caliper Pistons Using
Brake Caliper Piston Remover (Part No. B-42079)
5737