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Table of Contents
WHEELS, TIRES AND BRAKES
211
Pad wear depends greatly on riding habits and
conditions. See
Brake Pad Inspection
in
Chapter Three.
Always replace all pads (2 per disc) at the
same time.
Front Brake Pad Removal
(All 1981 Models and 1980 KZ550-C)/
Rear Brake Pad Removal
(All 1981 Models)
1. Remove the 2 caliper mounting bolts and
lift the caliper off the pad holder (Figure 44).
2.
Remove the brake pads.
Front Brake Pad Installation
(All 1981 Models and 1980 KZ550-C)/
Rear Brake Pad Installation
(All 1981 Models)
1. Remove the cap from the master cylinder
and slowly push the piston (Figure 45) into the
caliper while checking the reservoir to make
sure it doesn't overflow. The piston should
move freely. You may need to use a C-clamp to
push the piston back into the caliper. If the
piston sticks. remove the caliper and have it
rebuilt by your Kawasaki dealer.
2. Make sure the brake pad guides are in place
(Figure 46).
3. Install the pads with the friction material
toward the disc (Figure 47).
4. Make sure the anti-rattle spring is installed
in the caliper (Figure 48).
5. Install the caliper. Torque the caliper bolts
(Figure 44) as specified in Table 4.
a new hose. Place a new washer on each side of
each banjo bolt.
6. Support the motorcycle with the wheel off
the ground. Spin the wheel and pump the brake
until the pads are seated against the disc.
7. Top up the fluid level in the master cylinder
if necessary and reinstall the cap.
WARNING
Do nor rlde the r~ororcycle untd you are
w r e the brakes are ~ u r k ~ n g
wlth a sol~d
,feel. I f necessary, bleed the brakes to
reinow any accutnulut~d a u from the
sjlstein.
Front Brake Pad Removal
(1979-1980 KZ550-A, KZSCO)
1. Remove the
2
caliper mounting bolts
(Figure 49) and lift the caliper off the brake
disc.
2.
Remove the screw. lockwasher and plate
securing the inboard pad.
3.
Remove the inboard pad.
4. Slide the caliper holder toward the bleed
valve and remove the outboard pad.
NOTE
If the pad won't come out, squeeze the
brake lever a few times until the plston
pushes the pad out.
Front Brake Pad Installation
(1979-1980 KZ550-A, KZ500)
1. Remove the cap from the master cylinder
and slowly push the piston into the caliper
while checking the reservoir to make sure it
doesn't overflow. The piston should move
freely. You may need to use a C-clamp to push
the piston back into the caliper. If the piston
sticks, remove the caliper and have it rebuilt by
your Kawasaki dealer.
2. Install the outboard pad against the caliper
piston. with the stepped side ofthe pad toward
the disc (Figure 50).
3.
Install the inboard pad, aligning the tab on
the pad with the groove in the caliper (Figure
51). Use Loctite Lock N' Seal on the mounting
screw threads.
4. Install the caliper. Torque the caliper
mounting bolts as specified in Table 4.
5. Support the motorcycle with the front wheel
off the ground. Spin the front wheel and pump
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   Also See for Kawasaki KZ500

This manual is also suitable for:

Zx550Kz550Kzx550

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