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a
Prepare a container for brake flUid, and
perform
the
work
above.
o
Remove the front/rear caliper
wi
th
the banjo boll
tightened
lightly (see
Caliper Removal).
o
Remove the pads and spring (see Pad Removal).
Dlnsert
a wooden board 5 mm thick inside the
caliper
opening.
O
Pump
the brake
lever
or pedal to remove the caliper piston(s).
Assembly
.Clean
the
caliper
parts
excepllhe
pads.
CAUTION
For
cleaning
the
parts,
use only
disc brake
fluid,
Isopropyl alcohol,
or
ethyl
alcohol.
.Tighten
the
bleed
valve.
Torque
-
Caliper Bleed Valve: 7.8 N-m (0.80 kg-m,
69ln·lbl
Replace the flUid
seals
which are removed with new ones.
aApply
brake
fluid to the fluid
seals
[Al,
and install
them
into
the
cylinders by hand
.
Replace the dust seals
[BJ
with new ones
if
they are damaged.
QApply
brake fluid to the dust seals, and
install
them into the cylinders
by hand
.
Apply brake fluid to the outside of the piston(s)
[C],
and push them
into
each
cylinder
by hand
.
Replace the shaft rubber friction boot
[A]
and dust covet
[B)
if they
are damaged
.
Apply a thin coat of silicone or PBC grease to the caliper holder shafts
[C]
and holder holes
[0]
(PBC is a special high temperature,
water-resistant grease)
.
Install
the anti-rattle spring [A)
in
the
caliper as shown
.
Install the pads (see
Pads Installation)
.
Wash away
any
spilled brake fluid on
the
caliper.
BRAKES 10-13

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   Also See for Kawasaki KDX200

This manual is also suitable for:

Kdx220 1995-2006

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