2006 Buell Lightning: Chassis 2-35
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CLEANING AND INSPECTION
11WARNING1WARNING
Use denatured alcohol to clean brake system compo-
nents. Do not use mineral-based solvents (such as gaso-
line or paint thinner), which will deteriorate rubber parts
even after assembly. Deterioration of these components
can cause brake failure, which could result in death or
serious injury. (00291a).
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.
11WARNING1WARNING
Always replace brake pads in complete sets for correct
and safe brake operation. Improper brake operation
could result in death or serious injury. (00111a)
3. Inspect brake rotor and pads. See 1.6 BRAKE SYSTEM
MAINTENANCE.
4. Check rotor surface. Replace if warped or badly scored.
See Table 2-13.
ASSEMBLY
1. See Figure 2-48. Install pistons and o-rings.
a. Lubricate new o-rings (6), pistons (5), and caliper
piston bores with D.O.T. 4 BRAKE FLUID.
b. Install two new o-rings (6) in grooves of each piston
bore.
c. Install pistons (5) in each piston bore.
2. Install new o-rings (8) between caliper halves.
3. Clamp caliper together with caliper fasteners (11) and
tighten to 15-19 ft-lbs (20-26 Nm).
INSTALLATION
1. See Figure 2-48. Install brake pads (10).
2. Install pad spring (7) and pin hanger set (1) and tighten
to 11-14 ft-lbs (15-19 Nm).
3. Install caliper on caliper mount. Using LOCTITE 272
(red), tighten fasteners (9) to 35-37 ft-lbs (47-50 Nm).
Use only new copper crush banjo washers (See Parts
Catalog for Part No.) with D.O.T. 4 brake fluid. Earlier sil-
ver 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.
4. Install brake line to caliper. See 2.11 FRONT BRAKE
LINE.
5. Bleed front brakes. See BLEEDING BRAKES in 1.6
BRAKE SYSTEM MAINTENANCE.
Be sure that all lights and switches operate properly
before operating motorcycle. Low visibility of rider can
result in death or serious injury. (00316a)
6. Turn ignition key switch to ON. Apply brake hand lever to
test brake lamp operation.
Table 2-13. Front Rotor Runout
RUNOUT IN. MM
Rotor radial 0.0177 0.45
Rotor lateral 0.0248 0.63
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