WHEELS, TIRES AND BRAKES
1. Remove the tire from the rim.
2. Inspect the rim inner flange. Smooth any
scratches on the sealing surface with emery
cloth. Ifa scratch is deeper than 0.5 mm (0.020
in.), the wheel should be replaced.
Inspect the tire inside and out. Replace a tire
if any of the following is found:
a. A puncture larger than 1/8 in.
b. A punctured or damaged sidewall
c. More than
punctures in the tire
4. Apply the plug/patch, following the
instructions supplied with the patch.
Some models are equipped with hydraulic
disc brakes at the front and rear wheels and
some models have a hydraulic disc brake at the
front with a dl-um brake at the rear.
Repair of brake systems is extremely critical
work. Don't take shortcuts and don't work with
makeshift tools. When a procedure calls for a
locking agent, such as Loctite Lock N' Seal, use
it. Ifa torque specification is given, use a torque
wrench. Recheck your work and, when you're
finished, test your brakes in a safe area. If you
have any doubts about your ability to d o the
job according to these procedures. have the
work done by your Kawasaki dealer.
See Table 1 and Table 2 for brake wear
limits. See Table 4 for disc brake system torque
HYDRAULIC DISC BRAKES
Brake fluid is an irritant. Keep it away
jiorn your eyes and o f y o u r skin.
W'hen removing ~7heels with drum
brakes or when working on drum brakes,
be extremely careful not to inhale any of
the dust frow the brake linings. The
brake linings contain asbestos .fiber;
asbestos has been connected with lung
scarring a n d cancer. Do not use
compressed air to clean the drum or
linings. D u m p a n y dust onto a
newspaper and dispose of it in the trash.
Wash your hands after handling the
The following precautions
when servicing brake systems.
1 . Never reuse old brake fluid.
2. Never use fluid from a container that has
been left open.
Use only disc brake fluid clearly marked
DOT 3 or higher. Don't mix different rated
brake fluids together.
4. Don't leave the fluid reservoir cap off for
too long. The fluid will absorb moisture from
the air and will boil at lower temperatures.
5. Don't contaminate the brake discs or pads
with brake fluid. gasoline or any lubricants
(including graphite or pencil lead).
6. Brake fluid can ruin paint and plastic. Ifyou
spill any, wipe it up immediately.
7. If you open a bleed valve or loosen a brake
line fitting, bleed air from the system as
described in this chapter.
BRAKE SYSTEM BLEEDING
Bleed the hydraulic brake system whenever
the brake lever or pedal action feels spongy or
soft. after brake fluid has been changed or
whenever a brake line fitting has been
1. Remove the reservoir cap and add brake
fluid. Don't let the fluid level drop below the
minimum during this procedure or air will
enter the system and you'll have to start over.
2. Install the reservoir cap. Connect a clear
plastic hose to the bleed valve at the caliper
(Figure 37). Run the other end of the hose into
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