Service Manual (KLZ1000C) — page 341 of 762

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BRAKES 12-1

                                                            Brakes
                                                       Table of Contents
Exploded View........................................................................................................................          12-3
Specifications .........................................................................................................................       12-8
Special Tools ..........................................................................................................................       12-9
Brake Lever, Brake Pedal.......................................................................................................               12-10
   Brake Lever Position Adjustment......................................................................................                      12-10
   Brake Pedal Position Inspection .......................................................................................                    12-10
   Brake Pedal Position Adjustment......................................................................................                      12-10
   Brake Pedal Removal .......................................................................................................                12-10
   Brake Pedal Installation ....................................................................................................              12-11
Calipers ..................................................................................................................................   12-13
   Front Caliper Removal ......................................................................................................               12-13
   Front Caliper Installation ...................................................................................................             12-13
   Rear Caliper Removal.......................................................................................................                12-14
   Rear Caliper Installation....................................................................................................              12-14
   Front Caliper Disassembly................................................................................................                  12-15
   Front Caliper Assembly.....................................................................................................                12-15
   Rear Caliper Disassembly ................................................................................................                  12-15
   Rear Caliper Assembly .....................................................................................................                12-15
   Caliper Fluid Seal Damage Inspection..............................................................................                         12-16
   Caliper Dust Seal Damage Inspection ..............................................................................                         12-16
   Rear Caliper Dust Boot and Friction Boot Damage Inspection.........................................                                        12-16
   Caliper Piston and Cylinder Damage Inspection ..............................................................                               12-17
   Rear Caliper Holder Wear Inspection ...............................................................................                        12-17
Brake Pads .............................................................................................................................      12-18 12
   Front Brake Pad Removal.................................................................................................                   12-18
   Front Brake Pad Installation..............................................................................................                 12-18
   Rear Brake Pad Removal ................................................................................................                    12-18
   Rear Brake Pad Installation ..............................................................................................                 12-19
   Brake Pad Wear Inspection ..............................................................................................                   12-19
Master Cylinder ......................................................................................................................        12-20
   Front Master Cylinder Removal ........................................................................................                     12-20
   Front Master Cylinder Installation .....................................................................................                   12-20
   Rear Master Cylinder Removal.........................................................................................                      12-21
   Rear Master Cylinder Installation......................................................................................                    12-21
   Front Master Cylinder Disassembly ..................................................................................                       12-22
   Rear Master Cylinder Disassembly...................................................................................                        12-22
   Master Cylinder Assembly ................................................................................................                  12-22
   Master Cylinder Inspection (Visual Inspection).................................................................                            12-23
Brake Disc ..............................................................................................................................     12-24
   Brake Disc Removal .........................................................................................................               12-24
   Brake Disc Installation ......................................................................................................             12-24
   Brake Disc Wear ...............................................................................................................            12-25
   Brake Disc Warp ...............................................................................................................            12-25
Brake Fluid .............................................................................................................................     12-26
   Brake Fluid Level Inspection.............................................................................................                  12-26
   Brake Fluid Change ..........................................................................................................              12-26
   Brake Line Bleeding..........................................................................................................              12-26
Brake Hose.............................................................................................................................       12-30
   Brake Hose Removal/Installation......................................................................................                      12-30
   Brake Hose and Pipe Inspection.......................................................................................                      12-30