Kawasaki VULCAN 1600 CLASSIC (2003) [393/575] Brakes 12 23

BRAKES 12-23

Brake Discs

Brake Disc Removal

•

Remove the wheel (see Wheels/Tires chapter).

•

Unscrew the mounting bolts [A], and take off the disc.

Brake Disc Installation

•

Install the brake disc [A] on the wheel so that the marked

side [B] faces out.

•

Apply a non-permanent locking agent to the threads of

the brake disc bolts [C].

•

Tighten:

Torque - Brake Disc Bolts: 27 N·m (2.8 kgf·m, 20 ft·lb)

Brake Disc Wear

•

Measure the thickness of each disc [A] at the point where

it has worn the most.

Measuring Area [B]

Replace the disc if the sliding surface has worn past the

service limit.

Front Dis c Thick ness

Standard: 4.8 ∼ 5.2 mm (0.19 ∼ 0.20 in.)

Service Limit: 4.5 mm (0.18 i n. )

Rear Disk Thickness

Standard: 6.8 ∼ 7.2 mm (0.268 ∼ 0.283 in.)

Service Limit: 6.0 mm (0.24 in.)

Brake Disc Warp

•

Jack up the motorcycle so that the wheel is off the ground

(see Wheels/Tires chapter).

○

For front disc inspection, turn the handlebar fully to one

side.

•

Set up a dial gage against the disc [A] as shown and mea-

sure disc runout, while turning [B] the wheel by hand.

If the runout exceeds the service limit, replace the disc.

Disc Runout

Standard: TIR 0.15 mm (0.0059 in.) or less

Service Limit: TIR 0.3 mm (0.01 in.)