Kawasaki KX65 Motorcycle User Manual


 
10-12 BRAKES
Caliper
Caliper Removal
Front Brake
Loosen the banjo bolt [A] so as not to spill brake fluid.
Remove the caliper mounting bolts [B].
Remove the banjo bolt and take off the brake hose from
the c aliper [C].
If the caliper is to be disassembled after removal and if
compressed air is not available, remove the piston using
the following steps before disconnecting the brake hose
from the caliper.
Remove the pads.
Pump the brake lever to remove the piston.
Rear Brake
Unbolt the guard bolts and remove the rear caliper guard.
Loosen the banjo bolt [A] so as not to spill brake fluid.
Remove the caliper mounting bolts [B].
Remove the banjo bolt and take off the brake hose from
the c aliper [C].
If the caliper is to be disassembled after removal and if
compressed air is not available, remove the piston using
the following steps before disconnecting the brake hose
from the caliper.
Remove the pads.
Pump the brake lever to remove the piston.
CAUTION
Immediately wipe up any brake fluid that is spilled.
Caliper Installation
Tighten the brake pad bolts if they were removed.
Torque - Brake Pad Bolts: 18 N·m (1.8 kgf·m, 13 ft·lb)
Install the caliper, and the brake hose lower end.
Replace the washers that are on each side of hose fitting
with new ones.
Install the brake hose lower end so that the white paint
mark on it faces backward.
Torque - Caliper Mounting Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)
Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)
Bleed the brake line (see Bleeding the Brake Line).
Check the brake for good braking power, no brake drag,
and no fluid leakage.
WARNING
Do not attempt to drive the motorcycle until a full
brake lever or pedal is obtained by pumping the
brake lever or pedal until the pads are against the
disc. The brakes will not function on the first appli-
cation of the lever or pedal if this is not done.