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Kawasaki KZ1300-A1 Quick Reference Manual Page 132

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DISASSEMBLY -- CHASSIS
elnsert the other pin through caliper and pads. Press
down
the free end of each
spring
so that the
pin
can
pass over it.
A. Anti-rattle Spring
B. Pin
elnsert
the clips through the pins on the left side of
the left
pad.
elnstall
the pad cover.
eSince
some brake fluid was lost when the bleed valve
was
opened,
check the fluid level in the master cylinder
and bleed the air from the brake system
(Pg.
221).
Add fluid if
necessary.
ePush
the
bleed
valve cap onto the valve
.
I
I
Do not attempt to
ride
the motorcycle
~ARNING
until the pads are seated against the disc.
Pump the brake pedal until a firm, full
"feel" is
obtain·
ed. The brake will not function on the first application
of the pedal if this is not done.
Rear Caliper Disassembly:
eRemove
the rear caliper (see rear wheel removal
, Pg.
129).
eRemove
the pads as explained in the pad removal
section
(Pg.
131)
.
eRemove
the Allen bolts
CD
(2) and separate the right
caliper half
CD
.
A. Allen Bolts
eRemove
the
0
ring
(])
and the
dust
seals
CD
(2) around
the pistons.
A. Dust Seals
B.
"0"
Ring
eWrap
each caliper half with a
clean,
heavy
cloth,
and
remove each piston
®
by lightly applying compressed
air to the brake fluid passage.
I
WARNING
I
To avoid serious
injury,
ne~er
place
your
.,. _ _ _ _ II. fingers or palm on the piston.
If
you
apply compressed air into the caliper, the piston may
crush your hand or fingers.
eTaking
care not to damage the cylinder surfaces, re-
move the flu id seals
@
with a
hook.
Caliper Assembly:
eCiean
the caliper parts with brake fluid or alcohol
(See CAUTION
-
Pgs. 123 -124)
.
eFit
a new fluid seal in place inside each cylinder.
NOTE:
If the rubber caliper components are removed,
they should be replaced with new parts.
eApply
brake fluid to the outside of each
piston
and
fluid seal, and then push the piston into the cylinder
by
hand.
Take care that neither the cylinder nor the
piston
skirt are
scratched.
elnstall
a new dust seal around each piston. Check that
the
dust
seals are properly fitted into the grooves in the
piston
and the caliper halves.
eFit
a
new 0
ring onto the right caliper half, and install
the left caliper half with the Allen
bolts.
eTighten
the Allen bolts to 3.0 kg-m (22 ft-Ibs) of
torque.
elnstall
the pads as explained in the pad installation
section
(Pg. 131).
elnstall
the caliper and rear wheel (Pg.
129).
eCheck
the fluid level in the master
cylinder,
and bleed
the brake line
(Pg.
221).
Rear Master Cylinder and Rear Brake
Light Switch Removal:
eRemove
the right side cover.
ePull
off the rear brake light switch
leads.
-Remove
the banjo bolt and two flat washers to dis-
connect the brake hose from
master
cylinder. Imme-
diately wipe up any brake fluid that
spills.
132

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