Kawasaki Z1000SX - Service manual > Front Caliper Removal

Brakes / Calipers / Front Caliper Removal

  • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely.
  • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc.

NOTICE Do not loosen the caliper assembly bolts [D]. Take out only the caliper mounting bolts for caliper removal.

Loosening the caliper assembly bolts will cause brake fluid leakage.

Calipers

  • Unscrew the banjo bolt and remove the brake hose [E] from the caliper (see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter).

NOTICE Immediately wash away any brake fluid that spills.

Calipers

NOTE

  • If the caliper is to be disassembled after removal and if compressed air is not available, disassemble the caliper before the brake hose is removed (see Caliper Rubber Parts Replacement in the Periodic Maintenance chapter).

 

  • Remove the collars [A] from the fork leg.

Calipers

Rear Caliper Removal

  • Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely.
  • Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc.
  • Unscrew the banjo bolt and remove the brake hose [D] from the caliper (see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter).

NOTICE Immediately wash away any brake fluid that spills.

Calipers

NOTE

  • If the caliper is to be disassembled after removal and if compressed air is not available, disassemble the caliper before the brake hose is removed (see Caliper Rubber Parts Replacement in the Periodic Maintenance chapter).

Caliper Installation

  • Install the caliper and brake hose lower end.
    • For the front caliper, install the collars [A] on the fork leg and fit the holes [B] of the front caliper to the collars.
    • Replace the washers on each side of hose fitting with new ones.
  • Tighten:
    Torque -
     Caliper Mounting Bolts
      Front: 34 N*m (3.5 kgf*m, 25 ft*lb)
      Rear: 25 N*m (2.5 kgf*m, 18 ft*lb)
     Brake Hose Banjo Bolts: 25 N*m (2.5 kgf*m, 18 ft*lb)
  • Bleed the brake line (see Brake Line Bleeding).
  • Check the brake for good braking power, no brake drag, and no fluid leakage.

Calipers

WARNING After servicing, it takes several applications of the brake lever or pedal before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death. Do not attempt to ride the motorcycle until a firm brake lever or pedal is obtained by pumping the lever or pedal until the pads are against the disc.

Front Caliper Disassembly

  • Refer to the Caliper Rubber Parts Replacement in the Periodic Maintenance chapter.

Front Caliper Assembly

  • Refer to the Caliper Rubber Parts Replacement in the Periodic Maintenance chapter.

Rear Caliper Disassembly

  • Refer to the Caliper Rubber Parts Replacement in the Periodic Maintenance chapter.

Rear Caliper Assembly

  • Refer to the Caliper Rubber Parts Replacement in the Periodic Maintenance chapter.

    See also:

     Kawasaki Z1000SX - Service manual > Calipers

     Kawasaki Z1000SX - Service manual > Caliper Fluid Seal Damage

    The fluid seal (piston seal) [A] is placed around the piston to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the temperature of the discs or the brake fluid to increase. Replace the fluid seal if it exhibits any of the conditions listed below. Brake fluid leakage around the pad. Brakes overheat. Considerable difference in inner and outer pad wear. Seal and piston are stuck together.

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