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Rear Master Cylinder Installation; Front Master Cylinder Disassembly; Rear Master Cylinder Disassembly - Kawasaki KDX200 Service Manual

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Rear Master Cylinder Installation
e
Tighten the feaf master cylinder
mounting
screws
securelv_
Torque
-
Rear Master Cylinder Mounting
Screws:
8.3 N-m (0.85
kg-m,
74
ln.
lbj
Replace the cotter pin with a new one.
Replace the washers on each side of the hose fitting with new ones.
e
Torque the
following:
Torque
-
Brake Hose Banjo
Bolt:
25 N-m (2.5
kg-m,
18.0 ft.-lb)
Bleed the brake line (see Bleeding the Brake line) .
• Check t
he brake for good braking power, no brake drag, and no fluid
leakage.
• Check t
he brake pedal posi
tion.
Front Master Cylinder
Disassembly
Remove the
front master cylind
er.
Remove the
reservoir
cap
and d iaphrag
m,
and
pour the brake fl
u
id into
a
container
.
Unscrew the
locknut
[A]
and
pivot
bolt
[8]
.
and remove the brake
lever [C]
.
Push the dust cover [0] out
of
place,
and
remove the clrelip
[El.
Special Tool
-
Inside CirellI'
Pliers:
57001-143
Remove the washer [F], and pull
out
the
piston
assemblv [ G).
Do not remove the primary and secondary
cups
(H]
from the piston
since removal will damage them.
Rear
Master Cylinder
Disassembly
Remove the rear master cvlinder
.
Slide the dust
cover
(A] on the push rod [8) out of place, and remo .....
the cirelip [C]
.
SjMCial Tool
-
Inside CirellI'
Pliers:
57001 -143
Pull
out
the push rod with the
piston
stop [D).
.Take off the piston assemblv [ E] and return spring [F]
.
CAI1TION
Do not remove
the
primary and secondary
cups
[G]
from
the
piston
since removal will damaga
them.
eRemove the circlip [ H],
and
take off the connector [I] and O-ring
[J
J.
BRAKES 10-17

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   Also See for Kawasaki KDX200

This manual is also suitable for:

Kdx220 1995-2006

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