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92 DISASSEMBLY-CHASSIS
•Install a
new
grease
seal
using
a
bearing
driver (special
tool: PN57001-291) and bearing driver
holder.
Press
the
seal
in
so that the
face
of the seal is flush with the
surface of
the fron
t
hub.
•Install
the
cap
an
d
screws
(2).
•Place the disc on the
hu
b,
an
d install
the speedometer
gear drive, fitting it in the
hub
notches.
•Install
the speedometer gear dirve holding plate with
the
protruding side
facing
out.
A.
Hub Notches
C. Speedometer Gear Drive
B. Holding Plate
•Tighten the
disc
moutning
bolts
(4) to
3.0 kg-m
(22
ft-I bs)
of torque.
•After
installing
the
disc,
check
the
disc runout
(Pg.
150)
.
•Install the speedometer gear housing so
that it
fits
in
the
speedometer gear
drive notches (F ig.
GlO)
.
•Instal
l
the
collar on the right side of
the
hub.
•Carefu
ll
y clean
the
disc
with
a high flash-point solvent.
Do not
use
a solvent which
will
leave an
oily
residue.
FRONT BRAKE
Removal,
instal lation, disassembly, and assembly of
the front
disc brake
is
d
ivided
as follows:
Pad Removal
Pad
Installation
Caliper Removal
Caliper Installation
Notes
Caliper
Disassembly
Caliper
Assembly
Master Cylinder Removal
Master
Cylinder
Installation
Notes
Master Cylinder
Disassembly
· Master
Cylinder
Assembly
No
tes
Brake Hose
Replacemen
t
NOTE: Disc removal
and
disc
install
ation are covered in
front
huh disassemb ly
and
front
hub assembly sections
(Pg.
90).
Before
working
on
the
disc
brake,
take note
of the
following:
_
[@ilifil
1. ~:ece~~lyfo~is:hebr~~:
fi ~ ~~'
~;odpr:~;;
alcohol, or ethyl alcohol for cleaning brake parts.
Do not use any other fluid for cleaning these parts.
Gasoline, motor oil, or any other petroleum dis-
t
illate
will cause deterioration of the rubber parts.
Oil spilled on any part will
be
difficult to
wash
off
completely, and will eventually deteriorate
the
rubber used in the disc brake.
2. When handling the disc pads or disc, be careful that
no disc brake fluid or any oil gets on them. Clean
off any fluid or oil that inadvertently gets on
the
pads or disc with a high flash-point
solvent,
Replace
the pads with new ones if they cannot be cleaned
satisfactorily.
3. Brake fluid quickly ruins painted surfaces; any spilled
fluid should be completely
wiped
up immediately.
4. If any of the brake line fittings or the bleed valve is
opened at any time, AIR MUST BE BLED FROM
THE BRAKE SYSTEM (Pg. 146).
5. When installing or assembling the disc brake, tighten
the
disc brake fittings to the
values
given
in
Table G1.
Improper
torque
may cause the brake to malfunction.
Table G1
Disc Brake Torque (for Front and Rear)
kg-m
rt-lbs
Brake
lever pivot bolt
'
0.6
52 in-lbs
Master
cylinder
clamp
I
0.8
69
in-lbs
Fitting (banjo) bolts
3.0
22
Caliper holder
shaft
nuts
2.6
19
Caliper mounting bolts
3.0
22
Bleed valve
0.8
69
in-lbs
Disc
mounting
bolts
3.0
22
Rear
caliper Allen
bolts
3.0
22
Master cylinder
plug
(rear)
4.5
33
Pad Removal :
•Remove
the
caliper
mou nt ing
bolts, lockwashers, and
flat
washers (2 ea).
•Take ou
t
the
mounting screw
fo
r
pad B, and remove
the
pad. A lockwasher and metal
plate
also come off.
A.
Pad
A
C.
Mounting Screw
B.
Pad
B
•After
pad
B
is
removed,
slide the
caliper
holder
to
the
piston
side and
remove
pad A.
Pad
Installation:
•Rerriove
the
bleed valve cap,
open
(loosen)
the
valve
sligh tly,
push the
piston in
by
hand
as
far
as it
will
go, and then
close (tighten)
the
valve.
Wipe
up any
spilled
fluid, and
recap
the
bleed
valve.

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   Also See for Kawasaki Z250 1981

This manual is also suitable for:

Kz350 1981

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