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12. Clamp; Clamp Bolt - Kawasaki KZ500 Manual

1979-1985.
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Table of Contents
WHEELS, TIRES AND BRAKES
217
piston fluid seal and dust cover be replaced
every other time the pads are replaced.
Rebuilding a leaky caliper requires special
tools
and
experience.
W e
therefore
recommend that caliper service be entrusted to
your Kawasaki dealer or brake specialist. You
will save time, money and possibly your life by
removing the caliper yourself and having a
professional do the job.
See Table 1 at the end of the chapter for
brake wear limits.
WARNING
Do not ride the motorcvcle until you are
sure the brakes are operating properly.
Caliper Removal/Installation
Remove and install the calipers as described
under
Disc Brake Pad Replacement
or
Rear
Wheel Removal,
and
Brake
Line
Replacement
in this chapter.
MASTER CYLINDER REBUILDING
If the master cylinder leaks. it should be
rebuilt. If the piston sticks in the cylinder.
indicating severe wear or galling, the entire unit
should be replaced. Rapid darkening of fresh
brake fluid is an indication that rubber parts
inside the master cylinder have deteriorated.
Rebuilding a master cylinder requires
special tools and experience. We therefore
recommend that service be entrusted to your
Kawasaki dealer o r brake specialist. You will
save time. money. and possibly your life by
removing the master cylinder yourself and
having a professional d o the job.
See Table 1 at the end of the chapter for
brake wear limits.
FRONT MASTER CYLINDER
Removal
See Figure 58.
1. Remove the right rear view mirror.
2.
Push up on the front brake light switch
locking tab under the lever bracket (Figure
59)
and pull the switch free from the lever bracket.
FRONT MASTER CYLINDER
1. Cover screw (2)
8. Dust cover
15. Clamp bolt (2)
2.
Lever pivot bolt
9. Banjo bolt
16. Primary cup
10. Copper washers
17. Secondary cup
4.
Diaphragm
11. Brake hose
18. Piston
5. Lever
12. Clamp
19. Piston stop
6. Locknut
13. Washer
(2)
20. Dust seal
7. Bodyfreservoir
14. Spring
21. Liner
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