Buell P3 - After Repairing the Brake System, Test Brakes at Low; Banjo Bolt (Metric); Banjo Washers; Be Sure that All Lights and Switches Operate Properly

2-40 2007 Buell P3: Chassis
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INSTALLATION
1. See Figure 2-58. Install caliper mount clip (1) if removed.
2. See Figure 2-59. Install caliper assembly on caliper
mount. Brake pad surfaces must face rear brake rotor.
a. Apply Loctite Threadlocker 271 (red) to both caliper
mounting screws (6, 7) (metric).
b. Install large caliper screw (7) (metric). Tighten to 18-
22 ft-lbs (24-30 Nm).
c. Install small caliper screw (6) (metric). Tighten to
14.5-18 ft-lbs (20-24 Nm).
11WARNING1WARNING
Use only new copper banjo washers (See Parts Catalog
for Part No.) with D.O.T. 4 brake fluid. Earlier silver 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
CAUTION
Avoid leakage. Be sure gaskets, banjo bolt(s), brake line
and caliper bore are clean and undamaged before
assembly. (00321a)
3. Connect brake line (1) to caliper using two new banjo
washers (3) and banjo bolt (2) (metric). Tighten to 16-20
ft-lbs (22-27 Nm).
4. Depress rear brake pedal several times to set brake pads
to proper operating position within caliper. Bleed brake
system.
5. Verify proper fluid level in reservoir.
11WARNING1WARNING
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 IGN. Apply brake pedal to test
brake lamp operation. Turn ignition key switch to LOCK.
11WARNING1WARNING
After repairing the brake system, test brakes at low
speed. If brakes are not operating properly, testing at
high speeds can cause loss of control, which could
result in death or serious injury. (00289a)
NOTE
Avoid making hard stops for the first 100 miles (160 km) to
allow new brake pads to “wear in” properly with the brake
rotor.
Figure 2-58. Caliper Mount Clip
Figure 2-59. Rear Brake Caliper (Typical)
6486
1
2
1
. Clip
2
. Rear caliper mount
7723
2
4
1
1. Brake line
2. Banjo bolt (metric)
3. Banjo washers (2)
4. Bleeder valve (metric)
5. Pin plug and pad hanger (metric)
6. Small screw (metric)
7. Large screw (metric)
3
5
6
7