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Kawasaki KZ1300-A1 Quick Reference Manual Page 221

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MAINTENENCE--CHASSIS
eOose
the bleed valve(s), and fill the reservoir with
fresh
brake
fluid
.
eOpen
the bleed
valve,
apply the brake by the brake
lever or pedal, close the valve with the brake held
applied, and then quickly release the lever or pedal.
Repeat
this
operation
until the brake line is filled
and fluid starts coming out of the plastic hose.
Replenish the fluid in the reservoir as often as nec-
essary to keep it from running completely out.
eBleed
the air from the lines (See the next paragraph).
Bleeding
the
brake
The brake fluid has a very low compression coef-
ficient so that almost all the movement of the brake
lever or pedal is transmitted directly to the caliper
for braking action. Air, however, is easily compressed.
When air enters the brake lines, brake lever or pedal
movement will be partially used in compressing the
air.
This will make the lever or pedal feel spongy, and there
will be a loss in braking
power.
Bleed
the air from the brake whenever brake lever
or pedal action feels soft or spongy, after the brake
fluid is changed, or whenever a brake line fitting has
been loosened for any reason.
eRemove
the reservoir
cap,
and check that there is
plenty of fluid in the
reservoir.
The fluid level must
be checked several times during the bleeding operation
and replenished as
necessary.
If the fluid in the
reser-
voir runs completely out any time during bleeding, the
bleeding operation must be done over again from the
beginning since air will have entered the line.
Bleeding the Brake Line
1.
Hold the brake
applied.
2. Quickl
y
open and close the
valve.
3.
Release the brake.
eWith
the reservoir cap off, slowly pump the brake lever
or pedal several times until no air bubbles can be seen
riding up through the fluid from the holes at the
bottom of the
reservoir.
This bleeds the air from the
master cylinder end of the line.
elnstall
the reservoir
cap,
and connect a clear plastic
hose to the bleed valve at the caliper, running the other
end of the hose into a
container.
Pump the brake lever
or pedal a few times until it becomes hard and then,
holding the lever squeezed or the pedal pushed
down,
quickly open (turn counterclockwise) and close the
bleed valve. Then release the lever or pedal.
Repeat
this operation until no more air can be seen coming out
into the plastic
hose.
Check the fluid level in the
res-
ervoir every so often, replenishing it as necessary.
eFor
a dual disc
brake,
repeat the
previ
ous step one
more time for the other side
.
eAfter
air bleeding is finished, tighten the bleed valve to
0.80 kg-m (69 in-Ibs) of torque, and install the rubber
cap.
eCheck
the brake fluid level through the inspection
window in the reservoir. With the master cylinder held
level, the fluid should be filled more than level line
marked next to the window.
A. Inspection Window
B. Level Lines
Master Cylinder
Master cylinder parts
wear
When master cylinder parts are worn or damaged
,
proper
brake fluid pressure cannot be obtained in the
line, and the brake will not hold
.
If
the small relief port becomes
plugged,
especiall
y
with a swollen or damaged
primary cup,
the brake pads
will drag on the disc
.
eCheck
that there are no
scratches,
rust or pitting on
the inside
of
the master
cylinder,
and that it is not
worn past the service limit.
-Check
the pi,ston for these same
faults.
NOTE:
The cups are part
of
the piston assembl
y. Re-
place the piston assembl
y
if
any
one of the cups requires
replacement.
el
nspec
t
the
primary
and
secondary cups.
I f a cup is
worn
,
damaged
,
softened (rotted
),
or
swollen,
replace
it. When inserting the cup into the
cylinder,
see that
it is slightly larger than the cylinder (standard values
given in Table
J
7)
.
If fluid leakage is noted at
th
~
brake lever, the cups should be replaced.
221

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