Buell 2002 S3T, Service Manual

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2-22 2002 Buell S3T: Chassis
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CLEANING AND INSPECTION
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WARNING
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 brake operation
which could result in death or serious injury.
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 0.18 in. (4.5 mm).
b. Check rotor surface. Replace if warped or badly
scored.
1 1
WARNING
1
WARNING
Failure to install brake pads as a set may adversely affect
brake operation. Always replace brake pads in complete
sets for correct brake operation. Never replace just one
brake pad. Failure to comply could result in death or seri-
ous injury.
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 2-28. Install pistons and O-rings.
a. Apply a light coat of D.O.T. 4 BRAKE FLUID to O-
rings, pistons and caliper piston bores.
b. Install two new O-rings (6) in grooves of each piston
bore.
c. Install pistons (5) in each piston bore.
2. Install two new O-rings (3) between caliper halves.
3. Attach caliper halves together with four screws (7) (met-
ric). Tighten to 14.5-18 ft-lbs (20-24 Nm).
4. Install a new bleeder valve (4) (metric) if necessary.
Tighten to 3-5 ft-lbs (4-7 Nm).
INSTALLATION
1. Fit front brake caliper on rotor.
a. Check rotor attachment to carrier. Inspect all six
brake drive pins for missing hardware.
b. Make sure rotor is centered on carrier. Use two
clamps on rotor and carrier to reduce freeplay and
center rotor.
c. Slide caliper over front brake rotor without brake
pads installed.
2. See Figure 2-25. Apply LOCTITE THREADLOCKER 272
(red) to both caliper mounting screws (5). Install and
tighten to 22-25 ft-lbs (30-34 Nm).
3. Install brake pads.
a. See Figure 2-29. Insert brake pads from behind.
b. See Figure 2-26. Install pad spring (2) with opening
at top as shown.
Figure 2-27. Removing Pistons
Figure 2-28. Caliper O-rings and Pistons
6495
6482
1
2
7
5
4
3
3
1. Outside Caliper Half
2. Inside Caliper Half
3. O-Ring (2)
4. Bleeder Valve (metric)
5. Piston (3 sizes, 2 each)
6. Piston O-Rings (3 sizes, 2 each)
7. Screws (4) (metric)
6