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Rear Master Cylinder Installation Notes; Front Master Cylinder Disassembly - Kawasaki KX125 1990 Service Manual

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-
When
removing
the
brake
hose,
temporarily
secure
the
end
of
the
brake
hose
to some
high
place
to
keep
fluid
loss
to
a
minimum.
-
Unscrew the
master cylinder mounting
screws,
and
remove
the master
cyli
nder with
the
reservoir.
-
Unscrew the reservoir
cap screws, take off
the
reservoi
r
cap
(the diaphragm
comes off with
the
reservoir
cap) and
pour the
brake
fluid
into
a
container.
-
Remove
the
reservoir
and its
hose
from the master
cylinder.
Rear
Master Cylinder Installation Notes
-I
nsta
llation
is the reverse
of
removal.
-Tighten
the
master cylinder
mounting
screws
securely.
-
Use a
new flat washer
on
each
side of
the brake
hose fitting,
and
tighten the banjo
bolts to
the
specified
torque.
Tightening
Torque
25 N-m 12.5 kg-m
,
18 ft-Ibl
-Tighten the reservoir
mounting bolt
securely.
-
Sleed the brake
line after master cylinder
install ation
(see
Bleeding the
Brake
Lin
e~
-Check
the
brake
for weak braking
power,
brake drag.
and
fluid
leakage,
-Check the brake
pedal
position.
Front Master Cylinder Disassembly
-
Remove
the
front master
cylinder
(see Front
Master
Cylinder Removal)
-
Remove
the reservoir
cap and
diaphragm,
and
pour
the
brake
flu
id into
a
container.
-
Unscrew
the locknut
and pivot
bolt,
and
remove
the
brake
lever.
-
Push the dust cover
out
of pla
ce,
and using
circlip
pliers
(special
tool:
57001-143),
remove
the
circlip.
-
Remove
the washer,
and pullout
the
piston,
secondary cup,
primary
cup,
and
retum
spring.
CAUTION
Do not remove
the
secondary cup from
the
piston
since removal wHI
damage
it.
BRAKES
'0-
"
Front Master Cylinder
~!~~
8
G'~
®
5
1.
Dust
Cover
2.
Cl
rcll
p
3.
Washer
4.
Piston
5.
Secondary
Cup
6.
Primary
Cup
7.
Retum
Spring
8.
Reservoir
Rear
Master Cylinder
Disassembly
-
Remove
the rear
master cylinder
(see
Rear
Master
Cyl
inder
Removal).
-
Slide
the dust
cover
on the push
rod
out
of place, and
using circlip
pliers
(special
tool:
57001
-143),
remove
the
circlip.
-
Pull out the push rod
with the piston
stop.
-
Take
off
the piston,
secondary
cup,
primary
cup,
and
retu
rn
spring.
CAUTION
Do not
remove
the secondary cup from
the
piston
since
removal will damage
it.
-
Remove
the
cirdip,
and
take
off the
connector
and
O-ring.
Rear
Master Cylinder
9
1.
Push Rod
2.
Dust
Cover
3.
Piston
Stop
4.
Cird
ip
5.
Piston
6.
Secondary
Cup
7.
Primary
Cup
8.
Return Spring
9.
Master Cylinder
10.
O-Ring
11
.
Cirdip
12.
Connector

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