Kawasaki Z400 - Service manual > Master Cylinder

Front Master Cylinder Removal

• Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder (see Brake Hose Removal/Installation).
• Remove the damp bolts [B] and remove the master cylinder [C] with the reservoir, brake lever, and brake switch as an assembly.
• Disconnect the front brake light switch connector [D].

NOTICE

Brake fluid quickly damage painted plastic surfaces; any spilled fluid should be completely washed away Immediately.

Front Master Cylinder Installation

• Connect the front brake light switch connector.
• Set the front master cylinder to match its mating surface [A] to the punch mark [B] of the handlebar.
• The master cylinder damp must be installed with the arrow mark [C] upward.
• Tighten the upper damp bolt first, and then the lower damp bolt.

Torque - Front Master Cylinder Clamp Bolts: 8.8 Nm (0.90 kgf*m, 78 in*lb)

Replace the washers that are on each side of the hose fitting with new ones.

Tighten:

Torque - Brake Hose Banjo Bob: 25 N-m (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 RUM leakage.

Rear Master Cylinder Removal

• Loosen the brake hose banjo bolt [A] and rear master cylinder mounting bolts [B].
• Remove: Bolt PI Right Front Foot Peg Bracket Bolts [D] Brake Hose Banjo Bolt

NOTICE

Brake fluid quickly damage painted plastic surfaces; any spilled fluid should be completely washed away Immediately.

• Drain the brake fluid into a container.
• Turn the right front footpeg bracket inside out.
• Remove: Cotter Pin [A] Joint Pin [B] Rear Master Cylinder Mounting Bolts Rear Master Cylinder [C]

Rear Master Cylinder Installation

• Tighten : Torque -Rear Master Cylinder Mounting Bolts: 25 N*m (2.5 kgf*m, 18 ft*lb)
• Replace the cotter pin with a new one.
• Insert the joint pin from the outside.
• Insert the cotter pin and  bend the pin end [A].
• Install  the right front footpeg bracket, and tighten the bolts.

Torque- Front Footpeg Bracket Bolts: 25Nm(2.5 kgf*m, 18 ft*lb)

• Replace the washers that are on each side of hose fitting with new ones.
• Fit the brake hose fitting into the groove on the rear master cylinder.
• Tighten: Torque -Brake Hose Banjo Bolts: 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.

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.

Master Cylinder Inspection

• Remove the master cylinders (see Front/Rear Master Cylinder Removal).
•  Disassemble the front and rear master cylinders (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 each master cylinder and on the outside of each piston [B]

*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.

• 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.

Front Master Cylinder [J] Rear Master Cylinder [K]

See also: