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Kawasaki KZ1300-A1 Quick Reference Manual Page 127

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OISASSEMBL Y -- CHASSIS
ePosition
the caliper holder for installation. To avoid
damaging
the dust covers, carefully turn the caliper
holder shafts as they are inserted.
NOTE:
The bosses of the threaded holes for the caliper
mounting bolts
must
face the
piston
side.
A. Piston
B. Boss
elnstall
the spacers and nuts.
Finger tighten the nuts
loosely.
NOTE: Do
not forget to tighten the nuts after installing
the caliper on the motorcycle (Pg.125)
.
elnstall
pad A in the caliper holder.
eFit
pad
B,
aligning the tongue on the
pad
with the
groove in the caliper.
Install the metal plate, lock-
washer,
and mounting screw using a non-permanent
locking agent on the screw (Fig. G12).
Master Cylinder Removal:
eRemove
the brake fluid (Pg. 220).
eTake
off the right rear-view
mirror.
ePush
the front brake switch locking tab and remove
the switch.
ePull
back the dust
cover,
and remove the banjo bolt
to disconnect the upper brake hose from the master
cylinder.
There is a flat washer on each side of the
hose fitting.
A. Banjo Bolt
B. Clamp Bolts
eRemove
the clamp bolts (2), and take off the master
cylinder.
There
is a flat washer for each master cyl-
inder clamp bolt.
Immediately wipe
up
any
brake
fluid that
spills.
Master Cylinder Installation Notes:
1.
The
master cylinder clamp is installed with the small
projection
towards the throttle
grip.
Tighten
the
upper
clamp
bolt
first, and
then
the
lower
clamp
bolt, both
to
0.90 kg-m
(78
in-Ibs) of
torque.
A. Projection
2.
Banjo bolt
torque is 3.0 kg-m (22 ft-Ibs).
3.
Bleed
the
brake
line after master cylinder installation
(Pg.
221).
Master Cylinder Disassembly:
eRemove
the locknut
@
and
pivot bolt
CD,
and remove
the
brake
lever
CD.
eRemove the screws (2),
take
off
the
master cylinder
cap
®
and diaphragm
CD,
and empty
out
the
brake
fluid
.
eUsing
a
thin-bladed
screwdriver or
some other
suitable
tool, press in the
liner
tabs
which
catch in the
holes
in
the
master
cylinder, and remove the liners
@.
A. Tab
ePull
out the
piston @
and spring@
.
eRemove
the
spring
®,
dust
seal
@,
and
piston
stop
@from
the
piston.
Master Cylinder Assembly Notes:
1.
Before
assembly, clean all
parts including
the master
cylinder with
brake
fluid or alcohol {See
CAUTION
127

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