Brake system of motorcycle Kawasaki ZX600-J1 3 (ZX-6R, 2000-2002)

Brakes exploded view
B: Apply brake fluid. G: Apply grease. R: Replacement Parts. S: Follow the specific tightening sequence. Si: Apply silicone grease (ex. PBC grease) L: Apply a non-permanent locking agent. T1: 1.0 N·m (0.10 kg·m, 9 in·lb) T2: 1.5 N·m (0.15 kg·m. 13...

Brakes specifications
Item Standard Service Limit Brake lever, brake pedal: Brake lever position 5-way adjustable (to suit rider) — Brake lever free play Non-adjustable — Pedal free play Non-adjustable — Pedal position About 57 mm below footpeg top — Brake fluid: Grade...

Brake pedal position — inspection
Check that the brake pedal [A] is in the correct position. [B] Footpeg Pedal Position [C]: Standard: About 57 mm below top of footpeg. ★ If it is incorrect, adjust the brake pedal position.

Brake pedal position — adjustment
Note. Usually it is not necessary to adjust the pedal position, but always adjust it when the master cylinder is disassembled or pedal position is incorrect. Measure the length indicated in the figure. Length [A]: Standard: 65±1 mm ★ If it is...

Front caliper — removal
Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. Caution! Do not loosen the caliper assembly bolts [D]. Take out only the caliper...

Rear caliper — removal
Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely. Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc. Unscrew the banjo bolt and remove the brake hose [D] from the caliper (see Brake Hose...

Brake caliper — installation
Install the caliper and brake hose lower end. Replace the washers that are on each side of hose fitting with new ones. Tighten the caliper mounting bolts and banjo bolt. Torque: Caliper Mounting Bolts (Front): 34 N·m (3.5 kg·m, 25 ft·lb) Caliper...

Front caliper — disassembly
Loosen the front caliper assembly bolt [A] and banjo bolt [B], and tighten them loosely. Remove: Front Caliper [C] (see Caliper Removal ) Brake Pads Front Caliper Assembly Bolts O-rings Using compressed air, remove the pistons. One way to remove the...

Front caliper — assembly
Clean the caliper parts except for the pads. Caution! For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. Install the bleed valve and rubber cap. Torque - Bleed Valve: 7.8 N·m (0.80 kg·m, 69 in·lb) Replace the...

Rear caliper — disassembly
Remove the rear caliper. Remove the pads and anti-rattle spring (see Rear Brake Pad Removal ). Remove the piston insulator. Using compressed air, remove the piston. Cover the caliper opening with a clean, heavy cloth [А]. Remove the piston by...

Rear caliper — assembly
Clean the caliper parts except for the pads. Caution! For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol. Install the bleed valve and rubber cap. Torque - Bleed Valve: 7.8 N·m (0.80 kg·m, 69 in·lb) Replace the...

Front brake pad — removal and installation
Removal Unscrew the pad spring bolts [A], and remove the pad spring [В]. Draw out the clip [A], and take off the pad pin [В]. Remove the brake pads [С]. Installation Push the caliper pistons in by hand as far as they will go. Install the brake pads....

Rear brake pad — removal and installation
Removal Unscrew the caliper mounting bolts. Detach the caliper from the disc. Draw out the clip [A], and take off the pad pin [В]. Remove the brake pads [С]. Installation Push the caliper piston in by hand as far as it will go. Install the...

Brake lining wear
Check the lining thickness [A] of the pads in each caliper. ★ If the lining thickness of either pad is less than the service limit [B], replace both pads in the caliper as a set. Pad lining thickness. Standard: Front 4 mm Rear 5 mm Service Limit: 1...

Front master cylinder — removal and installation
Removal Loosen the reservoir bracket bolts [А]. Disconnect the front brake light switch connectors. Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder (see Brake Hose Removal/lnstallation ). Unscrew the clamp bolts [B],...

Rear master cylinder — removal and installation
Removal Unscrew the brake hose banjo bolt [A] on the master cylinder (see Brake Hose Removal/lnstallation ). Pull off the reservoir hose lower end [B], and drain the brake fluid into a container. Remove the cotter pin [C] and join pin [D]. Note. C...

Front master cylinder — disassembly
Remove the front master cylinder (see Front Master Cylinder Removal ). Remove the reservoir cap and diaphragm, and pour the brake fluid into a container. Unscrew the locknut and pivot bolt, and remove the brake lever. Push the dust cover out of...

Rear master cylinder — disassembly
Remove the rear master cylinder (see Rear Master Cylinder Removal ). Slide the dust cover on the push rod out of place, and remove the circlip. Special Tool - Inside Circlip Pliers: 57001-143 Pull out the push rod with the piston stop. Take off the...

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...

Master cylinder — visual inspection
Disassemble the front and rear master cylinders. Check that there are no scratches, rust or pitting on the inner wall of each master cylinder [A] and on the outside of each piston [В]. ★ If a master cylinder or piston shows any damage, replace them....

Brake disc — removal and installation
Removal Remove the wheel (see Wheels/Tires chapter ). Unscrew the mounting bolts [A], and take off the disc [В]. Installation Install the brake disc on the wheel so that the marked side faces out. Apply a non-permanent locking agent to the threads...

Brake disc wear
Measure the thickness of each disc at the point where it has worn the most. Replace the disc [A] if it has worn past the service limit. [B] Measuring Area Front disc thickness: Standard: 4.85-5.15 mm Service Limit: 4.5 mm Rear disc thickness:...

Brake disc warp
Jack up the motorcycle so that the wheel is off the ground. Special Tool - Jack: 57001-1238 For front disc inspection, turn the handlebar fully to one side. Set up a dial gauge against the disc [A] as shown and measure disc runout. [B] Turn the...

Brake fluid level inspection
Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [В]. Note. Hold the reservoir horizontal by turning the handlebar when checking brake fluid level. * if the fluid level is lower than the lower level...

Brake fluid change
Note. The procedure to change the front brake fluid is as follows. Changing the rear brake fluid is the same as for the front brake. Level the brake fluid reservoir. Remove the reservoir cap. Remove the rubber cap from the bleed valve [A] on the...

Bleeding the brake line
The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed When air enters the brake lines, brake...

Brake hose — removal and installation
Caution! Brake fluid quickly ruins painted or plastic surfaces; any spilled fluid should be completely wiped up immediately with wet cloth. When removing the brake hose, take care not to spill the brake fluid on the painted or plastic parts. When...