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•Taking care not to damage the cylinder surface,
remove
the flu id seal
(8)
with a hook.
Caliper Assembly:
•Clean the caliper parts with
brake
fluid or
alcohol
(See
CAUTION
-
Pg. 92).
•Fit a
new
fluid seal in place inside the cylinder.
NOTE:
It
is
recommended
that the fluid seal, which
is
removed, be replaced with a new one.
•Apply brake flu id
to
the outside of the piston and
the
fluid seal, and push the piston into the cylinder by
hand.
Take care that neither the cylinder nor the
piston skirt
get
scratched.
•Install
the
dust seal around the dust seal stop. Check
that the dust
seal is
properly fitted into
the
groove
in the piston and on the dust seal stop
.
Caliper
Dust
Seal
Dust Seal
Caliper
Piston
•Apply a thin coat of PBC (Poly Butyl Cuprysil)
grease
to the caliper holder shafts and
the
holder holes. (PBC
grease
is a special high temperature, water-resistant
grease).
NOTE:
Replace the dust covers and
O
rings if
they
are
damaged.
•With the caliper holder properly positioned, insert the
caliper holder
shafts while carefully
turning
the shafts
to prevent damage
to
the dust covers.
•Install the
spacers
and the nuts, and
tighten the
nuts
loosely.
NOTE;
Do not forget to tighten the nuts after installing
the
caliper on
the
motorcycle (Pg. 93).
•Install pad A
in
the caliper holder.
•Fit pad B, aligning the tongue on the pad with the
groove in the
caliper.
Install the metal plate, lock·
washer, and
mounting
screw using a non-permanent
locking agent on the screw
(Pg.
93).
Master Cylinder Removal:
•Take off the right
rear view
mirror.
•Using
a thin-bladed
screwdriver or some other suitable
tool,
press in the front brake switch tab which catches
DISASSEMBLY-CHASSIS 95
in
the
hole in the underside of
the brake
lever
holder,
and then
remove
the switch.
•Pull
back
the dust cover, and
remove
the banjo
bolt
to
disconnect
the
upper brake
hose
from
the
master
cylinder. There
is
a
flat
washer on each side of the
hose
fitting.
A. Banjo Bolt
C.
Clamp Bolts
B.
Clamp
•Remove
the
clamp bolts
(2),
and take off
the
master
cylinder. There
is
a
flat
washer for each master cylinder
clamp
bolt.
Immediately wipe up
any
brake
flui
d that
is spilled.
Master Cylinder Installation Notes:
l.
The master cylinder
clamp
is
installed with the small
projection facing
the
throttle grip.
Tighten
the upper
clamp bolt first, and then
the
lower clamp bolt,
to
0.8 kg-m
(69
in-lbs) of torque.
A.
Small
Projection
2. Bleed the brake
line
after master cylinder installation
(Pg. 146).
Master Cylinder Disassembly:
•Remove the screws (2), take off the master cylinder
cap
(~)
and
diaphragm
([:, and empty out
the
brake
fluid.
•Remove the
locknut
(19)
and pivot
bolt@
, and remove
the brake
lever(9).

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   Also See for Kawasaki Z250 1981

This manual is also suitable for:

Kz350 1981

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