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Table of Contents
A. Bleed Valve
•Install the
pad
A in the
caliper
holder
with
its
stepped
portion fac
ing
rearward
.
•Fit pad B,
al
ign
ing the
tongue
on
the
pad
with
the
groove in
the
caliper.
Install
the metal plate,
loc
k-
washer, and mounting screw;
using
a non-permanent
locking agent
on the screw.
A. Tongue
•Mount
the brake
caliper
and tighten the mounting
bolts
to 3.0
kg-m
(22 ft-lbs) of torque.
•Since
brake
fl
uid was
spilled
when
the
bleed valve
was opened,
check
the
fluid level
in
the
master cylinder
and bleed the
air
from the brake system (Pg.
146}.
Caliper Removal:
•If
the
caliper
is
to be
disassembled, loosen the
caliper
holder shaft
nuts (2).
A. Shaft Nuts
DISASSEMBLY-CHASSIS 93
•Remove
the banjo
bolt
at
the
cal iper, and temporarily
secure
the
end of the brake hose as
high
as
possible
to keep fluid loss to a minimum.
There
is
a flat washer
on
each side ofthe
hose
fitting.
•Remove
the mounting
bolts
(2),
each with a
flat
washer
and lockwasher,
and
take off the caliper.
Caliper
Installation
Notes:
1.
Tighten the mounting
bolts
to
3.0
kg-m
(22
ft-lbs}
of torque.
2. Tigh
ten the
caliper
holder
shaft
nuts to
2.6 kg-m
(
19
ft-I
bs)
of
torque.
3.
Connec
t the brake
hose
to the caliper
putti
ng a new
fla
t washer on each
side of
the brake
hose fitting.
Tighten the banjo bolt to 3.0
kg-m
(22 ft-lbs)
of
torque.
4.
Check
the
fluid
level
in
the master cylinder, and
bleed
the
brake line (Pg.
146).
I
WARNING •
The front brake lever mu_st
be
pum~ed
...,. - - - - • - to move the brake pads mto operating
position.
If this is not done, the first few applications
of the brake may be ineffective and an unsafe riding
condition could
result.
Caliper Disassembly:
•Take
out
the
mounting screw
(]'.
for pad B
H
,
and
remove
the pad. A
lock washer
(ED
and metal
plate
Tl
also come off.
•Remove the caliper
holder
shaft
nuts
c
~:
(2), and
pull
out
the cal iper holder shafts
(i)
(2)
and
the
spacers
(4)
(2) taking care not to
damage
the
dust
covers
1
1
(4). Remove
the
caliper
holder
@
,
and
push out
pad
A
(ii~.
{IA]:r}§J
::d ~~:~gs~a:,:~~e;
0
ea~:
s~~~t
i~~vue:~
a little at a time.
A. Caliper Holder
B. Dust Covers
•Remove the
dust seal
:).©
around
the
piston'
,
~;
.

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   Also See for Kawasaki Z250 1981

This manual is also suitable for:

Kz350 1981

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