2007 Buell Lightning: Maintenance 1-21
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BRAKE PAD REPLACEMENT
Front Pad Removal
1. See Figure 1-15. Loosen pin hanger (2) but do not
remove.
2. Rotate wheel so that caliper is centered between rotor
mounting fasteners (1).
3. Remove lower caliper mounting fastener (4) that secures
caliper to fork lower.
4. Loosen but do not remove upper caliper mounting fas-
tener (3) that secures caliper to fork lower.
5. Remove pin hanger (2).
6. Rotate caliper counterclockwise to allow access to outer
pad.
7. Remove outer pad from right side.
8. Remove inner pad from left side by pulling rearward,
rotating pad 90 degrees and pulling through wheel open-
ing.
Front Pad Installation
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.
1. Push pistons in with suitable tool such as a clean paint
scraper until fully seated in bores. Be careful not to dam-
age rotor.
2. Install new inner pad from left side of motorcycle.
3. Install new outer pad from right side of motorcycle.
4. See Figure 1-15. Install pin hanger (2) making sure it
engages hole on both pads and spring clip.
5. Rotate caliper clockwise to align mounting fastener hole.
6. See Figure 1-15. Install lower caliper mounting
fastener (4).
7. Apply LOCTITE 271 (red) and tighten both caliper
mounting fasteners (3, 4) to 35-37 ft-lbs (48-50 Nm).
8. Tighten pin (2) to 11-14 ft-lbs (15-19 Nm).
9. Check brake fluid level.
10. Install front master cylinder reservoir cap with gasket and
tighten fasteners to 9-13 in lbs. (1.0-1.5 Nm).
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 1-15. Front Brake Caliper
8346
1. Rotor mounting fastener (6)
2. Front caliper pin hanger
3. Upper caliper mounting fastener
4. Lower caliper mounting fastener
2
1
4
3
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