2002 Buell P3: Chassis 2-25
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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.
11WARNING1WARNING
Always replace brake pads in complete sets for correct
brake operation. Never replace just one brake pad. Fail-
ure to install brake pads as a set could result in death or
serious 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 2-39. Install pistons and O-rings.
a. Apply a light coat of D.O.T. 4 BRAKE FLUID to
seals, pistons and caliper piston bores.
b. Install two new seals in outer grooves of each piston
bore.
c. Install two new seals in inner grooves of each piston
bore.
d. Install pistons (3) in each piston bore.
2. Install a new bleeder valve (metric) if necessary. Tighten
to 3-5 ft-lbs (4-7 Nm).
Figure 2-37. Pad Spring
7702
1
2
1. Pad Hanger Pin (metric)
2. Pad Spring
Figure 2-38. Removing Pistons
Figure 2-39. Caliper O-rings and Pistons
7699
7700
1
3
3
2
4
1. Caliper
2. Inner Seals
3. Piston (2)
4. Outer Seals
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