Buell 2006LIGHTNING MODELS, Service Manual

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1-22 2006 Buell Lightning: Maintenance
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Rear Pad Removal
1. See Figure 1-16. Remove rear caliper pin plug (3) and
loosen pin (4).
2. Remove fastener securing p-clamp and brake line
assembly to swingarm.
NOTE
The XB12Ss model uses the rear fender to secure the brake
line and not a p-clamp. It will be necessary to remove the rear
fender. See
2.34 FENDERS .
3. Remove two mounting fasteners (1) securing brake cali-
per and carrier assembly to swingarm.
4. Lift caliper and carrier assembly up and off of rotor.
5. Remove hanger pin (4).
6. Remove inner and outer pads, being careful not to dis-
lodge pad spring.
Rear Pad Installation
1. See Figure 1-16. Check that retainer (2) is present.
2. See Figure 1-17. Check that pad spring is present.
Should pad spring become dislodged, install with widest
area of spring towards piston side of caliper.
NOTE
Before beginning this procedure it will be necessary to
remove the front master cylinder reservoir cap. As the pistons
are pushed back into the caliper, fluid level may rise more
than 1/8 in. (3.2 mm) You may have to remove fluid to allow
for this.
3. Push piston in with suitable tool such as a clean paint
scraper until fully seated in bore.
4. Install new inner and outer brake pads
5. See Figure 1-16. Install hanger pin (4) making sure pin
engages hole on both pads.
6. Install brake caliper and carrier assembly over rotor.
7. Apply LOCTITE 272 (red) and install two mounting fas-
teners (1) through swingarm into carrier and tighten to
24-26 ft-lbs (32.5-35 Nm).
8. Tighten hanger pin to 11-14 ft-lbs (14.9-18.9 Nm).
9. Install pin plug (3). Tighten plug to 24 in-lbs (3 Nm).
10. Install fastener securing p-clamp and brake line assem-
bly to swingarm and tighten to 36-60 in-lbs (4.1-6.8 Nm).
11. On XB12Ss models, install rear fender. See 2.34 FEND-
ERS.
12. Check fluid level.
NOTE
Avoid making hard stops for the first 100 miles (160 km) to
allow new brake pads to “wear in” properly with the rotor.
Figure 1-16. Rear Brake Caliper
Figure 1-17. Rear Brake Pad Spring
8348
1. Rear caliper mounting fasteners
2. Retainer
3. Rear caliper pin plug
4. Rear caliper hanger pin
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4
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2
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