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

Not For Resale
www.SmallEngineDiscount.com
12-18 BRAKES
Master Cylinder
Rear Master Cylinder Removal
• Unscrew the brake hose banjo bolt [A] on the master cylinder
(see Brake Hose Removal/Installation).
• Pull off the reservoir hose lower end [B], and drain the
brake fluid into a container.
Loosen the master cylinder mounting bolts [C] lightly.
• Remove the cotter pin [D].
NOTE
○Pull off the joint pin while pressing down the brake
pedal.
• Unscrew the master cylinder mounting bolts, and remove
the master cylinder.
Rear Master Cylinder Installation
Replace the cotter pin [A] with a new one.
• Replace the washers on each side of hose fitting with new
ones.
• Tighten the following bolts.
Torque - Rear Master Cylinder 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 Brake Line Bleeding in the Periodic
Maintenance chapter).
• Check the brake for good braking power, no brake drag,
and no fluid leakage.
Front Master Cylinder Disassembly
• Remove the front master cylinder (see Front Master Cylinder
Removal).
• Remove the reservoir cap and diaphragm, and pour the
brake fluid into a container.
• Unscrew the locknut and pivot bolt, and remove the brake
lever.
• Pull the dust cover [A] out of place, and remove the circlip
[B].
• Pull out the piston [C], secondary cup [D], primary cup [E],
and return spring [F].
CAUTION
Do not remove the secondary cup from the piston
since removal will damage it.