Buell S1 Lightning User Manual

2-25
REAR BRAKE CALIPER
REMOVAL/DISASSEMBLY
NOTE
Step 1 (draining fluid) is not required for caliper removal.
Drain brake fluid only when disassembling caliper.
1. See Figure 2-26. Open bleeder nipple cap on rear cali-
per. Install end of a length of plastic tubing over caliper
bleeder valve (2), while placing free end in a suitable
container. Open bleeder valve (metric) about 1/2-turn.
Pump brake pedal to drain brake fluid.
2. Remove both caliper mounting screws (11) (metric) and
washers (10) to free caliper from caliper mount.
3. Pump brake pedal until piston reaches its full travel.
Remove banjo bolt (1) (metric) and two gaskets (3) to
disconnect brake line from caliper. Discard gaskets.
4. Remove slave pad from rear pad bracket (9).
5. Remove rear pad bracket and dust boots (12, 13) from
rear caliper assembly (4).
6. Remove master brake pad (7) from piston (6).
NOTE
Do not remove piston from caliper unless there are signs of
hydraulic fluid leakage or piston is not operating properly. If
piston must be removed, proceed to Step 7.
1WARNING
When using air pressure to remove piston from caliper,
piston may be ejected with considerable force. Wear
safety glasses, heavy gloves and hold caliper with heavy
towel to prevent personal injury.
1CAUTION
Exercise care to avoid dropping piston on hard surface.
Any damage requires piston replacement.
7. Hold caliper with piston facing downward. Place a clean
shop towel under piston. Apply low air pressure to
hydraulic brake line inlet hole until piston is forced out
caliper bore. If piston is tight in bore, tap lightly around
caliper while applying air pressure.
8. Remove and discard O-ring (5) from groove within piston
bore.
Figure 2-26. Rear Brake Pads and Caliper
1
Rear caliper rebuild kit,
Part No. 44149-94Y
3
2
4
5
6
7
8
9
10
12
13
11
1. Banjo bolt (metric)
2. Bleeder valve (metric)
3. Gaskets (2)
4. Rear caliper assembly
5. O-ring
6. Piston
7. Master brake pad
8. Slave brake pad
9. Rear pad bracket
10. Washer (2)
11. Screw (2) (metric)
12. Large dust boot
13. Small dust boot
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Buell S1 Lightning Specifications

General

Transmission	5-speed
Rear Brakes	Single 230mm disc, single-piston caliper
Compression Ratio	10.0:1
Ignition	Electronic
Engine Type	Air-cooled, four-stroke, 45° V-twin
Rear Suspension	Showa monoshock, adjustable preload, compression and rebound damping
Front Brakes	Single 340mm disc, 6-piston caliper
Seat Height	775 mm
Bore x Stroke	88.8 mm x 96.8 mm
Fuel System	Carburetor
Frame	Tubular steel
Tires	Front: 120/70 ZR17, Rear: 170/60 ZR17