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Kawasaki Z250 1981 Service Manual Page 103

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•Remove the banjo bolts
at the
cal
iper
and
master
cylinder,
and remove
the
brake
hose.
There is
a
fl
at
washer
on each side
of the
hose fi
tting.
•Connect the
new
brake
hose to the
caliper and master
cylinder,
putting
a
new flat washer on each side of the
brake hose
fittings.
•Fil
l
the
reservoir
with fresh brake
flu
id,
and bleed the
brake
line (Pg. 145).
DRIVE
CHAIN
Removal:
•Check
to
see
that
the
transmission is in neutral.
•Remove the engine sprocket cover
(Pg.
54). The clutch
cable
does
not
require
removal
from
the clutch
release.
•Remove the clip from the drive chain master link using
pliers,
and
remove the master
link.
A.
Clip
B.
Master Link
•Free the
drive
chain from the
sprockets,
being careful
that
the chain does not
get
dirty
from
contact
with
the ground.
Installation:
•Fit the
drive
chain back onto the sprockets with the
ends
at
the
rear
sprocket.
•Install the
master
link.
•Install
the
master link clip with pliers. The
direction
of
the
master link
clip
must be
as shown.
I
WARNING • Incorrect
installation
of the master link
. . . . . .
----111.
clip
can
allow
it to catch on an adjacent
part.
If
the
clip
dislodges, the chain could come
apart,
and this
could result
in
rear wheel lockup
and
loss of
control.
Master Link Clip Installation
Direction of Chain Rotation
~
Clip
•Install the engine
sprocket cover
(Pg.
54).
•Adjust
the drive
chain (Pg. 24).
•Adjust
the
rear orake (Pg. 25).
REAR WHEEL
Removal:
DISASSEMBLY-CHASSIS 97
•Raise
the rear
wheel
off
the ground.
•Remove
the
clip and master
link
from
the drive chain,
and
remove
the drive chain from
the
rear
sprocket.
•Remove the
locknut
,rnd
bol
t.
at the
rear end
of
the
torque link.
A. Torque Link
B. Locknut
•Loosen
the rear axle nut,
and
remove the
rear
wheel
together with the
rear
caliper by pulling them toward
the rear.
A. Caliper
•Remove the axle nut and
left
chain adjuster. Then
pu
ll
off the axle
with
the
right
chain adjuster while holding
up
the
caliper.
•Free the caliper
from
the disc, and
insert
a wood wedge
(4
~
5
mm thick) between the disc
brake
pads.
This
prevents them
from
being moved out of their proper
position, should the
brake
pedal
be pushed
accidentally.
§:iIEJ
~;c~
0
~~i~ !~~
~=~~g:
0
o~nw~~p
t : ~e
b~~s~~
Place blocks under the wheel so the disc does not touch
the ground.
•Fit the caliper
to
the
torque
link, and
run
the
axle
through
the
swing
arm and
the cal iper
holder
to pre-
vent the caliper
from dangling.
•The rear caliper
can
be
removed
by disconnecting
the
rear
end
of the
brake
hose
from the
caliper.

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Kz350 1981

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