buell s1 lightning '97 Manual
2-26
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.
Clean brake system components using denatured alco-
hol. Blow dry using compressed air. Carefully inspect all
components. Replace any parts that appear damaged or
worn. Replace rubber dust boots (12, 13) if damaged or
worn. Do not hone caliper piston bore.
hol. Blow dry using compressed air. Carefully inspect all
components. Replace any parts that appear damaged or
worn. Replace rubber dust boots (12, 13) if damaged or
worn. Do not hone caliper piston bore.
2.
Inspect brake rotor. Replace rotor if warped or badly
scored. Measure rotor thickness for excessive wear.
Replace rotors less than 0.19 in. (4.8 mm) thick.
scored. Measure rotor thickness for excessive wear.
Replace rotors less than 0.19 in. (4.8 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 excessive wear.
Replace both pads as a set if friction material of either
pad is worn to 1/16 in. (1.6 mm) or less.
Replace both pads as a set if friction material of either
pad is worn to 1/16 in. (1.6 mm) or less.
ASSEMBLY
1.
See
Install new O-ring (5) within groove in
piston bore of rear caliper assembly (4).
2.
Apply light coat of D.O.T. 5 SILICONE HYDRAULIC
BRAKE FLUID to piston OD, including chamfer. Apply a
light coat to caliper piston bore (6) and ID of installed pis-
ton O-ring (5). Install piston into caliper piston bore. Use
a “C” clamp to press in piston, if necessary.
BRAKE FLUID to piston OD, including chamfer. Apply a
light coat to caliper piston bore (6) and ID of installed pis-
ton O-ring (5). Install piston into caliper piston bore. Use
a “C” clamp to press in piston, if necessary.
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.
the caliper is installed, piston must be pressed all the way into
the bore whenever new brake pads are used.
3.
Install master brake pad (7) on piston (6).
4.
Install dust boots (12, 13) and rear pad bracket (9) into
rear caliper assembly.
rear caliper assembly.
5.
Install slave brake pad (8).
INSTALLATION
1.
With friction material facing brake rotor, align rear caliper
assembly on mounting bracket.
assembly on mounting bracket.
2.
See
Install washers and screws (metric) to
fasten rear caliper assembly to mounting bracket.
Tighten screws to 18-22 ft-lbs (24.4-29.8 Nm).
Tighten screws to 18-22 ft-lbs (24.4-29.8 Nm).
3.
Install bleeder valve (metric) if removed. Tighten valve to
6-9 ft-lbs (8.1-12.2 Nm). Install bleeder cap.
6-9 ft-lbs (8.1-12.2 Nm). Install bleeder cap.
4.
Position new gaskets on each side of banjo fitting. Insert
banjo bolt (metric) through gaskets and banjo fitting into
caliper. Tighten banjo bolt (metric) to 9.5-12.5 ft-lbs
(12.9-17.0 Nm).
banjo bolt (metric) through gaskets and banjo fitting into
caliper. Tighten banjo bolt (metric) to 9.5-12.5 ft-lbs
(12.9-17.0 Nm).
5.
With the master cylinder in a level position, check that the
brake fluid level is between the upper and lower marks
on reservoir. See
brake fluid level is between the upper and lower marks
on reservoir. See
Add D.O.T. 5 SILICONE
HYDRAULIC BRAKE FLUID if necessary. Be sure cap is
securely screwed on.
securely screwed on.
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.
6.
Depress rear brake pedal several times to set brake pads
to proper operating position within caliper. Bleed brake
system. See
to proper operating position within caliper. Bleed brake
system. See
BRAKES
in Section 1.
7.
Verify proper reservoir fluid level as described in Step 5.
8.
Test brake lamp operation with the rear brake pedal
applied and the ignition/headlamp switch turned to IGN.
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).