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Kawasaki KZ1300-A1 Quick Reference Manual Page 125

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DISASSEMBLY -- CHASSIS
elnstall
the
caliper,
tightening the caliper mounting bolts
to 3 .0 kg-m (22 ft-Ibs) of torque.
eSince
brake fluid was drained when the bleed valve was
opened, check the fluid level in the master cylinder
and
bleed
the air from the brake system (Pg. 221)
.
eCheck
the front brake.
I
WARNING
I
Do not ride th~ motorcyc!e until the pads
...,. ____ I.
are seated against the diSCS.
Pump the
brake lever several times until a full, firm lever
ufeel"
is obtained. The brakes
will
not function on the first
application of the
lever if
this
is
not done.
Caliper Removal
(each
side):
eRemove
the brake fluid
(Pg.
220)
.
eWhen
the left side caliper is to be removed, disconnect
the lower end of the speedometer cable.
elf
the caliper is to be disassembled, loosen the caliper
holder shafts
(2).
A. Shafts
C. Speedometer
Cable
B. Banjo Bolt
eRemove the banjo bolt at the caliper, and temporarily
elevate the end of the brake hose above the caliper to
prevent fluid loss minimum. There is a flat washer on
each side of the hose fitting.
eRemove the mounting bolts (2), and take off the
caliper.
Caliper Installation Notes:
1. Tighten the mounting bolts to 3.0 kg-m (22 ft-Ibs)
of torque.
2. Tighten the caliper holder shaft nuts to 2.6 kg-m
(19.0 ft-Ibs) of torque.
3. Put a new flat washer on each side of the brake hose
fitting and connect the brake hose to the caliper.
Tighten the banjo bolt to 3.0 kg-m (22 ft-Ibs) of
torque.
4. Check the fluid level in the master cylinder, and bleed
the brake line (Pg. 221).
I
WARNING
I
Do
not ride
th~
motorcyc.le until the pads
...,. _ _ _ _ I.
are seated against
the diSCS.
Pump the
brake lever
several times
until
a full, firm lever ufeel"
is obtained. The brakes
will
not function on the first
application of the lever if this is not done.
Caliper Disassembly:
eTake
out the mounting screw
@
for pad B
@,
and
remove the
pad.
A lockwasher
@
and metal plate
(i])
also come off.
eRemove
the nuts
<D
(2), and pull out the caliper holder
shafts
CD
(2) and the spacers
CD
(2) taking care not
to
damage
the
dust
covers
@
(4).
Remove
the caliper
holder
Q])
, and
push
out pad A
@
.
~ ~;er~:;!~y ~~~;:ew !~c~h:ha~~s~ I~t~~:r:~
a time.
A. Caliper Holder
C. Holder
Shafts
B. Dust Covers
eRemove
the
dust
seal
CD
around the
pistonCD.
-Cover the caliper opening with a
clean,
heavy cloth,
and
remove the
piston by lightly applying
com-
pressed air to where
the
brake line fits
into the
cylinder.
I
WARNING
I
To av~id serious inju'"! •. never place
L. _ _ _ _
I.
your fingers or palm Inside the cal·
iper opening.
If you blow compressed air into the
caliper, the piston may crush your hand or fingers.
NOTE: If compressed
air
is not available
.
reconnect
the
brake line
and
pump the piston out with
the
brake lever.
eTaking care not to damage the cylinder surface, remove
the fluid seal
(j)
with a hook.
125

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