3. When removing the fork assembly on
ZX550-A1 models, disconnect the hydraulic
reassembly, refer to Brake System Bleeding in
this supplement and bleed the brakes and
anti-dive unit as described.
(ZX550-A1 AND A2)
The anti-dive assembly consists of 2 basic
components; the brake plunger (A, Figure 84)
and the anti-dive valve (B, Figure 84).
Neither component is repairable. If a
component is defective and the anti-dive
function does not operate correctly, the faulty
component must be replaced.
Anti-dive unit adjustment procedures that
can be performed by the home mechanic are
described in the Chapter Three section of this
Visually inspect the anti-dive unit for fork
oil or brake fluid leakage.
If the anti-dive unit is leaking fork oil,
replace the 0-seals installed between the
anti-dive unit and the lower fork tube as
described in this chapter.
If the anti-dive unit is leaking brake
fluid, check the tightness of the air bleed
screws. Also check the condition of all
brake line attachments at the anti-dive
housing. If these checks prove okay, the
brake plunger is probably damaged or
working incorrectly. Replace the brake
plunger as described in this supplement.
1. Remove the bolts securing the brake
plunger assembly to the anti-dive valve (A,
Figure 84). Carefully remove the plunger
assembly. Take care not to damage the O-ring
between the plunger and the anti-dive valve.
2. Loosen one of the fittings on the metal
brake line and shift the plunger assembly
around until the plunger rod inside the
assembly is accessible. Retighten the brake
line fitting enough to keep the fluid from
Do not attempt to move the plunger
assembly without first loosening one of
the fittings on the metal brake line or
the brake line will be bent and
Take care not to spill brake fluid on the
painted surfaces ofthe front forks or the
paint may be damaged.
3. Hold your finger over the plunger rod and
apply the front brake slightly. Check that the
plunger rod extends approximately 2 mm
(0.08 in.) as the front brake is applied. Release
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