Buell 2002 S3T, Service Manual

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2002 Buell S3T: Chassis 2-29
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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 0.04 in. (1.0 mm) or less.
ASSEMBLY
1. See Figure 2-40. Place clip (1) inside caliper body as
shown.
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. See Figure 2-41. 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 (3) inside caliper body.
3. See Figure 2-40. Install brake pads (3) using pad hanger
and pin plug (1).
a. Install pad hanger pin (metric). Tighten to 11-14.5 ft-
lbs (15-20 Nm).
b. Install pin plug. Tighten to 1.5-2.1 ft-lbs (2-3 Nm).
4. Install a new bleeder valve (metric) if necessary. Tighten
to 3-5 ft-lbs (4-7 Nm).
INSTALLATION
1. See Figure 2-39. Install caliper mount clip (1) if removed.
2. See Figure 2-38. Install caliper assembly on caliper
mount. Brake pad surfaces must face rear brake rotor.
a. Apply LOCTITE THREADLOCKER 272 (red) to both
caliper mounting screws (6, 7) (metric).
b. Install large caliper screw (7) (metric). Tighten to 18-
22 ft-lbs (24-30 Nm)
c. Install small caliper screw (6) (metric). Tighten to
14.5-18 ft-lbs (20-24 Nm).
1 1
WARNING
1
WARNING
Use only copper crush 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.
1 1
WARNING
1
WARNING
Any leak in brake system will adversely affect brake
operation. To avoid leakage, verify that gaskets, banjo
bolt, hydraulic brake line and caliper bore are completely
clean. Failure to comply could result in death or serious
injury.
3. Connect brake line (1) to caliper using two new banjo
washers (3) and banjo bolt (2) (metric). Tighten to 16-
20 ft-lbs (22-27 Nm).
4. Depress rear brake pedal several times to set brake
pads to proper operating position within caliper. Bleed
brake system. See
1.5 BRAKES .
5. Verify proper fluid level in reservoir.
1 1
WARNING
1
WARNING
Check for proper brake lamp operation before riding
motorcycle (see Step 6). Visibility is a major concern for
motorcyclists. Failure to have proper brake lamp opera-
tion could result in death or serious injury.
6. Turn ignition key switch to IGN. Apply brake pedal to test
brake lamp operation. Turn ignition key switch to LOCK.
NOTE
Avoid making hard stops for the first 100 miles (160 km) to
allow
new brake pads to “wear in” properly with the brake
rotor.
Figure 2-40. Brake Pads
Figure 2-41. Removing Rear Brake Caliper Piston
6487
3
1
2
1. Clip
2. Pin Plug and Pad Hanger (metric)
3. Brake Pads (2)
6487
1
1. Brake Caliper Piston Remover
2. Adaptor
3. Piston
2
3