Kawasaki J300 - Service manual > Master Cylinder

Master Cylinder Removal

• Remove:
  Rear View Mirror (see Rear View Mirror Removal in the Frame chapter)
  Upper Handlebar Cover (see Handlebar Cover Removal in the Frame chapter)
• Remove the brake hose banjo bolt [A] and remove the brake hose from the master cylinder.
• Disconnect the front brake light switch connectors [B].

• Remove the clamp bolts [A], and take off the master cylinder as an assembly with the reservoir, brake lever and front brake light switch installed.

NOTICE Immediately wash away any brake fluid that spills.

• Remove:
  Locknut [A] and Brake Lever Pivot Bolt [B]
  Brake Lever [C]
  Front Brake Light Switch [D]

Master Cylinder Installation

• Apply silicone grease to the sliding surface of the brake lever pivot bolt.
• Install the brake lever, and tighten the brake lever pivot bolt and locknut.

  Torque -
   Brake Lever Pivot Bolt: 2.0 N*m (0.20 kgf*m, 18 in*lb)
   Brake Lever Pivot Bolt Locknut: 9.8 N*m (1.0 kgf*m, 87 in*lb)

• Install the front brake light switch.

  Torque - Brake Light Switch Screw: 1.0 N*m (0.10 kgf*m, 8.9 in*lb)

• Install the master cylinder to the handlebars.
  • Fit the projection [A] into a hole [B] in the handlebars.
• Tighten the upper clamp bolt first, and then lower clamp bolt.

  Torque - Master Cylinder Clamp Bolts: 12 N*m (1.2 kgf*m, 106 in*lb)

• Replace the washers that are on each side of the hose fitting with new ones.
• Tighten the brake hose banjo bolt.

  Torque - Brake Hose Banjo Bolt: 34 N*m (3.5 kgf*m, 25 ft*lb)

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

Master Cylinder Disassembly

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

Master Cylinder Assembly

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

Master Cylinder Inspection (Visual Inspection)

• Remove the master cylinder (see Master Cylinder Removal).
• Disassemble the master cylinder (see Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter).
• Check that there are no scratches, rust or pitting on the inner wall [A] of the master cylinder and on the outside of the piston [B].

  If a master cylinder or piston shows any damage, replace it.

• Inspect the primary cup [C] and secondary cup [D].

If a cup is worn, damaged softened (rotted), or swollen, the piston assembly should be replaced to renew the cups.

If fluid leakage is noted at the brake lever, the piston assembly should be replaced to renew the cups.

• Check the dust cover [E] for damage.

  If it is damaged, replace it.

• Check the piston return spring [F] for any damage.

  If the it is damaged, replace it.

• Check that relief port [G] and supply port [H] are not plugged.

  If the relief port becomes plugged, the brake pads will drag on the disc. Blow the ports clean with compressed air.

See also: