Kawasaki KX65 Motorcycle User Manual


 
BRAKES 10-13
Caliper
Caliper Disassembly
Remove the front/rear caliper (see Caliper removal).
Remove the pads and spring (see Pad Removal).
Remove the caliper holder, shaft rubber friction boot and
cover.
Using compressed air, remove the piston(s).
Cover the caliper opening with a clean, heavy cloth [A].
Remove the piston(s) by lightly applying compressed air
[B] to the hose joint opening.
WARNING
To avoid serious injury, never place your fingers or
palm inside the caliper opening. If you apply com-
pressed air into the caliper, the piston(s) may crush
your hand or fingers.
NOTE
If the caliper is to be disassembled after removal and
compressed air is not available, remove the piston(s)
using the following three steps before disconnecting the
brake hose from the caliper.
Prepare a container for brake fluid, and perform the
work above it.
Remove the pads and spring (see Pad Removal).
Pump the brake lever or pedal to remove the caliper
piston(s).
Remove the dust seal(s) and fluid seal(s).
Remove the bleed valve and rubber cap.
Caliper Assembly
Clean the caliper parts except for the pads.
CAUTION
For cleaning the parts, use only disc brake fluid,
isopropyl alcohol, or ethyl alcohol.
Tighten the bleed valve with rubber cap.
Torque - Caliper Bleed Valve: 7.8 N·m (0.8 kgf·m, 69 in·lb)
Replace the fluid seal which is removed with new one.
Apply brake fluid to the fluid seal [B], and install it into the
cylinder by hand.
Replace the dust seal with new one if it is damaged.
Apply brake fluid to the dust seal [A], and install it into the
cylinder by hand.
Apply brake fluid to the outside of the piston [C], and push
it into the cylinder by hand.