2007 Buell Lightning: Chassis 2-43
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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.
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. Refer to Table 2-13.
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)
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 2-58. 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. 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 inside caliper body.
NOTE
See Figure 2-60. Always make sure brake pad retainer is in
place on caliper mount before installing pads and caliper.
3. See Figure 2-58. Install brake pads (3) using pad hanger
and pin plug (2).
a. Install pad hanger pin (metric). Tighten to 11-14 ft-
lbs (15-19 Nm).
b. Install pin plug. Tighten to 24 in-lbs (2.7 Nm).
4. Install a new bleeder valve (metric) if necessary and
tighten to 36-60 in-lbs (4-7 Nm).
Table 2-13. Rear Rotor Runout
RUNOUT IN. MM
Rotor radial 0.0177 0.45
Rotor lateral 0.0154 0.39
Figure 2-60. Retainer, Brake Pads
6486
1
2
1. Retainer, brake pads
2. Rear caliper mount
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