Kawasaki VN1600 CLASSIC (2003) [384/575] 14 brakes

12-14 BRAKES

Calipers

•

Insert a wooden board [A] 5 mm (0.2 in.) thick inside the

caliper opening.

•

Pump the brake pedal until the pistons [B] push the

wooden board.

•

Remove the board and pull out the pistons [A] by hand.

○

These pistons can also be removed by disconnecting the

hose and applying compressed air to the hose joint open-

ing using the same wooden board. But be careful not to

put your fingers or palm inside the caliper opening during

work.

WARNING

To avoid serious injury, never place your fingers or

palm inside the caliper opening. If you apply com-

pressed air into the caliper, the pistons m ay crush

your hand or fingers.

CAUTION

Immediately wash away any brake fluid that spills.

•

Remove the anti rattle spring [A].

•

Remove the dust seals [B] and fluid seals [C].

•

Remove the rubber friction boots [D].

•

Remove the bleed valve [E] and rubber cap [F].

Rear Caliper Assembly

•

Tighten the bleed valve.

Torque - Caliper Bleed Valve: 7.8 N·m (0.8 kgf·m, 69 in·lb)

○

It is recommended that the fluid seal (piston seal) w hich

is removed, be replaced with a new one.

•

Replace the dust seals [A] if they are damaged.

•

Install the fluid seal [B]. Either side of the seal may face

outboard.