Front master cylinder disassembly
Remove the front master cylinder (see Front master cylinder removal in the Brakes chapter).
Remove the reservoir cap [A], plate [B], and diaphragm [C].
Unscrew the locknut [D] and pivot bolt [E], and remove the brake lever.
Pull the dust cover [F] out of place, and remove the circlip [G].
Special Tool - Inside Circlip Pliers: 57001-143.
Pull out the piston assy [H], and return spring [I].
![](https://motoinstruction.ru/img/kawasaki/13/118641.jpg)
Replace:
- Diaphragm
- Dust Cover
- Circlip
- Piston Assy
Rear master cylinder disassembly
Note. Do not remove the push rod clevis [A] for master cylinder disassembly since removal requires brake pedal position adjustment.
Remove the rear master cylinder (see Rear master cylinder removal in the Brakes chapter).
Remove the reservoir cap [B] plate [C] and diaphragm [D].
Slide the dust cover [E] on the push rod out of place, and remove the circlip [F].
Special Tool - Inside Circlip Pliers: 57001-143.
Pull out the push rod with the piston stop.
Take off the piston assy [G] (piston [H] primary cup [I], secondary cup [J]), and return spring [K].
![](https://motoinstruction.ru/img/kawasaki/13/118642.jpg)
Replace:
- Piston Assy
- Dust Cover
- Brake Hose [L]
- Diaphragm
- O-ring [M]
- Circlips
Master cylinder assembly
Before assembly, clean all parts including the master cylinder with brake fluid or alcohol.
Caution! Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, engine oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the disc brake.
Apply brake fluid to the removed parts and to the inner wall of the cylinder.
Take care not to scratch the piston or the inner wall of the cylinder.
Caution! Do not remove the secondary cup from the piston since removal will damage it.
Tighten the brake lever pivot bolt and the locknut.
Silicone Grease - Brake Lever Pivot Bolt, Brake Lever Pivot Contact, Push Rod Contact, Dust Cover
Torque:
- Brake Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 8.8 in·lb)
- Brake Lever Pivot Locknut: 5.9 N·m (0.60 kgf·m, 52 in·lb)