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Kawasaki Z250 1981 Service Manual Page 109

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Table of Contents
I
WARNING
I
To avoid serious injury, never place your
'-· - - - - • - fingers or palm on
the
piston.
If
you
apply compressed air into the caliper, the piston may
crush your
hand
or
fingers.
•Taking
care not to
damage the cylinder
surfaces, re·
move
the
fluid seals
with
a
hook.
Caliper
Assembly:
•Clean
the
cal iper
parts
with
brake flu id
or alcohol
(See
CAUTION
-
Pg. 92).
•Fit
a
new fluid
seal in
place
inside
each
cylinder.
NOTE:
It
is
recommended
that
you
rep
I
ace any
rubber
parts
that have been
removed.
•Apply
brake fluid to
the outside of each piston
,tnd
flu
id
seal,
and
then
push
the
piston into the
cyl inder
by hand
.
Take care
that
neither
the cyl inder nor the
piston
skirt
is scratched.
•Install
a new
dust
seal
around each piston.
Check that
the dust seals are
properly
fitted
into the grooves
in
the piston
and
the
caliper
halves.
•Fit a
new
O
ring
o
nto the righ
t
caliper
half,
and
install
the
left caliper
half
with
the
Allen bolts.
•Tighten
the Al len
bolts to 3.0
kg-m (22
ft-lbs)
of
torque.
•Instal
l
the
pads
as explained
in
the
pad
instal lation
section
(Pg.
92).
•Install the
re.
a r
wheel
(Pg.
97).
•Adjust
the
drive
chain
(Pg.
24).
•Check
the
flu[d level
in
the master
cylinder,
and
bleed
the brake line
(Pg. 145).
Rear Master Cylinder Removal:
•Pu
II
off the
right
side cover.
•Remove the
banjo bolt to disconnect the brake hose
from
the
master cylinder. There is a flat washer
on
each
side
of the
hose
fitting.
Immediately
wipe
up
any brake fluid
that
spills.
A. Banjo Bolt
•Remove
the master
cy
linder
mounting
bolts, lock-
washers,
and
flat
washers
(2
ea),
and
free the rear
master
(;,ylindcr from
the
motorcycle.
Rear Master
Cylinder Installation
Notes:
l.
Replace the flat
washer on
each
side
of
the
brake
hose
fitting
with new
ones.
2.
Bleed the
brake
line after
master cylinder
installation
(Pg.
146).
3. Adjust the
rear brake (Pg. 25).
DISASSEMBLY-CHASSIS
103
Rear Master
Cylinder
Disassembly:
•Remove
the push
rod
dL1st cover
'i
~;
.
•Take off the master cylinder cap ([ and diaphragm
(~~,
and
empty
the
brake
fluid
into
a
suitable
container.
•Remove the
retainer
,
1
·s,,
with
a
thin
screwdriver,
and
pull
out
the
piston stop
13)
and piston
11).
Do not
rem
ove
the secondary cup
1}
from
the piston
since
removal
will
damage
the
cup.
A.
Retainer
•Remove
the return spring
o'
\
§)
and primary cup
' .
i))
by
ligh
tly
app
ly
ing
compressed
air
into the outlet hole.
Rear Master
Cylinder
Assembly:
•Before assembly,
clean a[[ parts
including
the
master
cylinder
with
brake
fluid or
alcohol
(See CAUTION
-
Pg.
92), and
apply
brake
fl
uid
to
the parts
and
the
inner
wall
of
the
cylinder.
Take care not to
scratch
the
piston or
the
inner
wall
of
the
cy linder.
•Pu
t
the return spring into the cylinder.
The
spring
seat
side must face
out.
•Instal
l
the
primary cup. Be sure that the
primary
cup
is
not
installed
backward or
turned
sideways after
insertion.
A.
Master Cylinder
B. Spring
C. Primary Cup
0. Secondary Cup
E. Piston
•Install
the piston and
stop, and with a suitable rod,
install the retainer to
hold
the piston in as
far as
it
will
go.
•Instal
l
the diaphragm and the master
cylinder
cap.

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   Also See for Kawasaki Z250 1981

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Kz350 1981

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