Front Master Cylinder Removal
- Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder [B] (See Brake Hose and Pipe Replacement in the Periodic Maintenance chapter).
![](https://motoinstruction.ru/img/kawasaki/23/128824.jpg)
- Disconnect the front brake light switch connectors [A].
- Unscrew the clamp bolts [B], and take off the master cylinder as an assembly with the reservoir, brake lever and brake switch installed.
Caution: Immediately wash away any brake fluid that spills.
![](https://motoinstruction.ru/img/kawasaki/23/128825.jpg)
Remove:
- Brake Lever Pivot Bolt [A] and Locknut
- Brake Lever [B]
- Front Brake Light Switch [C]
![](https://motoinstruction.ru/img/kawasaki/23/128826.jpg)
Front Master Cylinder Installation
- Install the front master cylinder so that the punch mark [A] of the handlebar is aligned with the mating surface [B] of the master cylinder clamp to level the reservoir.
![](https://motoinstruction.ru/img/kawasaki/23/128827.jpg)
- The master cylinder clamp must be installed with the arrow mark [A] upward.
- Tighten the upper clamp bolt [B] first, and then the lower clamp bolt [C].
There will be a gap at the lower part of the clamp after tightening.
Torque - Front Master Cylinder Clamp Bolts: 8.8 Nm (0.90 kgf·m 78 in·lb)
- Replace the washers on each side of the hose fitting with new ones.
- Tighten the brake hose banjo bolt.
Torque - Brake Hose Banjo Bolt: 25 Nm (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.
![](https://motoinstruction.ru/img/kawasaki/23/128828.jpg)
Rear Master Cylinder Removal
Remove:
- Cotter Pin [A]
- Joint Pin [B]
Note: Pull off the joint pin while pressing down the brake pedal.
![](https://motoinstruction.ru/img/kawasaki/23/128829.jpg)
- Unscrew the brake hose banjo bolt [A] on the master cylinder (See Brake Hose and Pipe Replacement in the Periodic Maintenance chapter).
- Remove the master cylinder mounting bolts [B].
![](https://motoinstruction.ru/img/kawasaki/23/128830.jpg)
- Slide the reservoir hose lower end clamp [A].
- Pull off the reservoir hose lower end, and drain the brake fluid into a container.
![](https://motoinstruction.ru/img/kawasaki/23/128831.jpg)
Rear Master Cylinder Installation
- Replace the cotter pin [A] with a new one.
![](https://motoinstruction.ru/img/kawasaki/23/128832.jpg)
- Replace the washers on each side of hose fitting with new ones.
- Tighten the following bolts
Torque - Rear Master Cylinder Mounting Bolts: 25 Nm (2.5 kgf·m 18 ft·lb)
Brake Hose Banjo Bolt: 25 Nm (2.5 kgf·m, 18 ft·lb)
Note: Depress the brake pedal [A] and then align the bolts holes of the master cylinder [B].
- Bleed the brake line (See Brake Line Bleeding).
- Check the brake for good braking power, no brake drag, and no fluid leakage.
Front Master Cylinder Disassembly
- Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter.
Rear 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.
![](https://motoinstruction.ru/img/kawasaki/23/128833.jpg)
Master Cylinder Inspection
- Remove the master cylinders (see Front/Rear Master Cylinder Removal).
- Disassemble the front and rear master cylinders.
- Check that there are no scratches, rust or pitting on the inner wall [A] of each master cylinder and on the outside of each piston [B].
![](https://motoinstruction.ru/img/kawasaki/23/128834.jpg)
If a master cylinder or piston shows any damage, replace them.
- 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.
- KLE650A Models [J]
- KLE650B Models [K]
![](https://motoinstruction.ru/img/kawasaki/23/128835.jpg)
- Check the dust covers [E] for damage.
If they are damaged, replace them.
- Check the piston return springs [F] for any damage.
If the springs are damaged, replace them.
- 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.
![](https://motoinstruction.ru/img/kawasaki/23/128836.jpg)