Kawasaki Z1000 - ZR1000 2003-04 Service Manual - Small Engine ...

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Master Cylinder
BRAKES 12-17
Front Master Cylinder Removal
Disconnect the front brake light switch connectors [A].
• Remove the banjo bolt [B] to disconnect the brake hose
from the master cylinder [C] (see Brake Hose Removal/Installation).
• Remove the rear view mirror (see Steering chapter).
• Unscrew the clamp bolts [A], and take off the master cylinder
as an assembly with the reservoir, brake lever, and
brake switch installed.
Front Master Cylinder Installation
• Install the front master cylinder so that the punch mark [A]
of the handlebar is aligned with the mating surface [B] of
the master cylinder clamp to level the reservoir.
• The master cylinder clamp must be installed with the arrow
mark [A] upward.
• Tighten the upper clamp bolt [B] first, and then the lower
clamp bolt [C]. There will be a gap at the lower part of the
clamp after tightening.
Torque - Front Master Cylinder Clamp Bolts: 8.8 N·m (0.9
kgf·m, 78 in·lb)
• Replace the washers on each side of the hose fitting with
new ones.
• Tighten the brake hose banjo bolt.
Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)
• Bleed the brake line (see Brake Line Bleeding in the Periodic
Maintenance chapter).
• Check the brake for good braking power, no brake drag,
and no fluid leakage.
• Install the rear view mirror (see Steering chapter).