Kawasaki KX65 Motorcycle User Manual

10-14 BRAKES
Install the anti-rattle spring [A] in the caliper as shown.
Replace the shaft rubber boot and dust cover if they are
Apply a thin coat of silicone grease to the c aliper holder
shafts and holder holes (PBC is a special high tempera-
ture, water-resistant grease).
Install the pads (see Pads Installation).
Wipe up any spilled brake fluid on the caliper.
Fluid Seal Damage Inspection
The fluid seal around the piston maintains the proper
pad/disc clearance. If this seal is not in good condition,
pad wear will increase, and constant pad drag on the disc
will raise brake and brake fluid temperature.
Replace the fluid seals under any of the following condi-
tions: (a) fluid leakage around the pad; (b) brakes over-
heat; (c) there is a large difference in left and right pad
wear; (d) the seal is stuck to the piston. If the fluid seal is
replaced, replace the dust seal as well. Also, replace all
seals every other time the pads are changed.
Dust Seal and Cover Damage Inspectio n
Check that the dust seals and covers are not cracked,
worn, swollen, or otherwise damaged.
If they show any damage, replace them.
Piston Cylin der Damage Inspection
Visually inspect the piston and cylinder surfaces.
Replace the cylinder and piston if they are badly scored
or rusty.
Caliper Holder Shaft Wear Inspection
The caliper body must slide smoothly on the caliper holder
shafts. If the body does not slide smoothly, one pad will
wear more than the other, pad wear will increase, and con-
stant drag on the disc will raise brake and brake fluid tem-
Check to s ee if the caliper holder shafts are not badly worn
or stepped, or the rubber boot is not damaged.
If the shafts or rubber boot are damaged, replace the
shafts, rubber boot, and the caliper holder.