Kawasaki J300 - Service manual > Brake Lever, Brake Pedal, Calipers

Brake Lever, Brake Pedal

Brake Lever Position Adjustment

The brake lever adjuster has 4 positions so that the brake lever position can be adjusted to suit the operator's hand.

• Push the lever forward and turn the adjuster [A] to align the number with the mark [B] on the lever.
  • The distance from the grip to the lever is minimum at number 1 and maximum at number 4.

Calipers

Front Caliper Removal

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

NOTICE Immediately wash away any brake fluid that spills.

Rear Caliper Removal

• Remove:
  Muffler Body (see Muffler Body Removal in the Engine Top chapter)
  Mud Guard (see Mud Guard Removal in the Frame chapter)
• Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely.
• Remove the caliper mounting bolts [B], and remove the caliper [C] from the disc.
• Unscrew the banjo bolt and remove the brake hoses from the caliper (see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter).

NOTICE Immediately wash away any brake fluid that spills.

Caliper Installation

• Install the caliper and brake hose lower end.
  • Replace the washers on each side of hose fitting with new ones.
• Apply a non-permanent locking agent to the caliper mounting bolts.
• Tighten:

Torque -
 Front Caliper Mounting Bolts: 34 N*m (3.5 kgf*m, 25 ft*lb)
 Rear Caliper Mounting Bolts: 34 N*m (3.5 kgf*m, 25 ft*lb)
 Brake Hose Banjo Bolts: 34 N*m (3.5 kgf*m, 25 ft*lb)

• Install the removed parts (see appropriate chapters).
• Check the fluid level in the brake reservoirs.
• Bleed the brake line (see Brake Line Bleeding).
• Check the brake for good braking power, no brake drag, and no fluid leakage.

WARNING After servicing, it takes several applications of the brake lever 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 is obtained by pumping the lever 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.

Caliper Fluid Seal Damage Inspection

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.

  If the fluid seal is replaced, replace the dust seal [B] as well. Also, replace all seals every other time the pads are changed.

Caliper Dust Seal Damage Inspection

• Check that the dust seals [A] are not cracked, worn, swollen, or otherwise damaged.

  If they show any damage, replace the dust seals with new ones.

  Fluid Seals [B]

Caliper Friction Boot Damage Inspection

• Check that the friction boots [A] are not cracked, worn, swollen, or otherwise damaged.

  If they show any damage, replace them.

Caliper Piston and Cylinder Damage Inspection

• Visually inspect the pistons [A] and cylinder surfaces [B].

  Replace the caliper if the cylinder and piston are badly scores or rusty.

Caliper Holder Shaft Wear Inspection

The caliper body must slide smoothly on the caliper holder shafts [A]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and constant drag on the disc will raise brake and brake fluid temperature.

• Check to see that the caliper holder shafts are not badly worn or stepped, and that the friction boots are not damaged.

  If the caliper holder pin is damage, inspect the caliper holder for warp or deformation. If the caliper holder is in good condition, replace the caliper holder pins.

See also: