![Kawasaki NINJA ZX-6R (2000-2002) [202/332] 8 brakes](/img/pdf.png)
Kawasaki NINJA ZX-6R (2000-2002) [202/332] 8 brakes
![Kawasaki NINJA ZX-6R (2000-2002) [202/332] 8 brakes](/views2/1121199/page202/bgca.png)
Содержание
- Kawasaki 1
- Quick reference guide 2
- Table of contents 2
- List of abbreviations 4
- Read owner s manual before operating 4
- Emission control information 5
- Tampering with noise control system prohibited 6
- Awarning 7
- Foreward 7
- Foreword 7
- How to use this manual 7
- General info 9
- General information 9
- General information 1 1 9
- Table of contents 9
- 2 general information 10
- Before servicing 10
- Before servicing 11
- General information 1 3 11
- Red _______ 11
- Wire cross section name of wire color 11
- Wire strands 11
- Yellow red 11
- 4 general information 12
- Model identification 12
- General information 1 5 13
- General specifications 13
- 6 general information 14
- General specifications 14
- General information 1 7 15
- Periodic maintenance chart 15
- 8 general information 16
- Exhaust gas after purification 16
- Kawasaki low exhaust emission system 16
- Technical information kleen kawasaki low exhaust emission 16
- Exhaust gas before purification 17
- General information 1 9 17
- Technical information kleen kawasaki low exhaust emission 17
- 10 general information 18
- Catalytic converters 18
- Technical information kleen kawasaki low exhaust emissiqnj 18
- Fuel cut valve 19
- General information 1 11 19
- Performance of catalyst protection system 19
- Technical information kleen kawasaki low exhaust emission 19
- 12 general information 20
- Technical information kleen kawasaki low exh austemission 20
- General information 1 13 21
- Technical information kleen kawasaki low exhaust emission 21
- 14 general information 22
- Secondary air injection system 22
- Technical information kleen kawasaki low exhaust emission 22
- General information 1 15 23
- Technical information kleen kawasaki low exhaust emission 23
- 16 general information 24
- Technical information kleen kawasaki low exhaust 24
- Construction operation 25
- Details 25
- General information 1 17 25
- Technical information non contact hall ic type speed sensor 25
- 18 general information 26
- Technical information non contact hall ic type speed sensor 26
- Main characters 27
- Rare magnet material 27
- Technical information alternator made from rare magnet 27
- ______________________________________ general information 1 19 27
- 20 general information 28
- Basic torque for general fasteners 28
- Torque and locking agent 28
- General information 1 21 29
- Torque and locking agent 29
- 22 general information 30
- Torque and locking agent 30
- General information 1 23 31
- Torque and locking agent 31
- 24 general information 32
- Special tools and sealant 32
- General information 1 25 33
- Special tools and sealant 33
- 26 general information 34
- Special tools and sealant 34
- General information 1 27 35
- Special tools and sealant 35
- 28 general information 36
- Special tools and sealant 36
- General information 1 29 37
- Special tools and sealant 37
- 30 general information 38
- Cable wire and hose routing 38
- Cable wire and hose routing 39
- General information 1 31 39
- 32 general information 40
- Cable wire and hose routing 40
- Cable wire and hose routing 41
- General information 1 33 41
- 34 general information 42
- Cable wire and hose routing 42
- Cable wire and hose routing 43
- General information 1 35 43
- 36 general information 44
- Cable wire and hose routing 44
- Cable wire and hose routing 45
- General information 1 37 45
- 38 general information 46
- Cable wire and hose routing 46
- Cable wire and hose routing 47
- General information 1 39 47
- Fuel system 49
- Fuel system 2 1 49
- Table of contents 49
- 2 fuel system 50
- Exploded view 50
- Exploded view 51
- Fuel system 2 3 51
- 4 fuel system 52
- Exploded view 52
- Fuel system 2 5 53
- Specifications 53
- 6 fuel system 54
- Throttle grip and cables 54
- Choke cable 55
- Fuel system 2 7 55
- 8 fuel system 56
- Carburetors 56
- A warning 57
- Carburetors 57
- Fuel system 2 9 57
- 10 fuel system 58
- Carburetors 58
- Warning 58
- A warning 59
- Carburetors 59
- Fuel system 2 11 59
- 12 fuel system carburetors 60
- A warning 60
- Warning 60
- Carburetors 61
- Caution 61
- Fuel system 2 13 61
- 14 fuel system 62
- A warning 62
- Carburetors 62
- Caution 62
- _______________________caution ____________________ 62
- Carburetors 63
- Fuel system 2 15 63
- 16 fuel system carburetors 64
- Air cleaner 65
- Fuel system 2 17 65
- Warning 65
- 18 fuel system 66
- Air cleaner 66
- Fuel system 2 19 67
- Fuel tank 67
- 20 fuel system 68
- A warning 68
- Fuel tank 68
- A warning 69
- Fuel pump fuel filter 69
- Fuel system 2 21 69
- 22 fuel system____________________________ 70
- Evaporative emission control system california model only 70
- Evaporative emission control system california model only 71
- Fuel system 2 23 71
- 24 fuel system____________________________ 72
- Evaporative emission control system california model only 72
- Cooling system 73
- Cooling system 3 1 73
- Table of contents 73
- 2 cooling system 74
- Exploded view 74
- Specifications 75
- ______________________________________________cooling system 3 3 75
- 4 cooling system 76
- Coolant flow chart 76
- Coolant flow chart 77
- Cooling system 3 5 77
- 6 cooling system 78
- Coolant 78
- Warning 78
- Caution 79
- Coolant 79
- Cooling system 3 7 79
- 8 cooling system 80
- Caution 80
- Coolant 80
- Caution 81
- Coolant 81
- Cooling system 3 9 81
- 10 cooling system 82
- Water pump 82
- Cooling system 3 11 83
- Radiator radiator fan 83
- Warning 83
- 12 cooling system 84
- Caution 84
- Radiator radiator fan 84
- Cooling system 3 13 85
- Thermostat 85
- 14 cooling system 86
- Hose and pipes 86
- Caution 87
- Radiator fan switch water temperature sensor 87
- ___________________________________ _________ cooling system 3 15 87
- Engine top end 89
- Engine top end 4 1 89
- Table of contents 89
- 2 engine top end 90
- Exploded view 90
- Engine top end 4 3 91
- Exploded view 91
- 4 engine top end 92
- Specifications 92
- Specifications 93
- _____________________________________________ engine top end 4 5 93
- 6 engine top end 94
- Clean air system 94
- Clean air system 95
- Engine top end 4 7 95
- 8 engine top end 96
- Caution 96
- Cylinder head cover 96
- Cylinder head cover 97
- Engine top end 4 9 97
- 10 engine top end 98
- Camshaft chain tensioner 98
- Caution 98
- Camshaft camshaft chain 99
- Caution 99
- Engine top end 4 11 99
- 12 engine top end 100
- Camshaft camshaft chain 100
- Camshaft camshaft chain 101
- Engine top end 4 13 101
- 14 engine top end 102
- Camshaft camshaft chain 102
- Cylinder head 103
- Engine top end 4 15 103
- 16 engine top end 104
- Cylinder head 104
- Engine top end 4 17 105
- Valves 105
- 18 engine top end 106
- Caution 106
- Valves 106
- Engine top end 4 19 107
- Example present shim is 3 5 mm measured clearance is 0 5 mm replace 3 5 mm shim with 3 5 mm shim 107
- Give the proper clearance 107
- Horizontal column 107
- Install the shim specified where the lines intersect this shim will 107
- Measure the clearance when engine is cold 2 check present shim size 3 match clearance in vertical column with present shim size in 107
- Remeasure the valve clearance and readjust if necessary 107
- Valve clearance adjustment chart inlet valve 107
- Valves 107
- 20 engine top end__________________ 108
- Example present shim is 3 0 mm measured clearance is 0 0 mm replace 3 0 mm shim with 3 mm shim 108
- Give the proper clearance 108
- Horizontal column 108
- Install the shim specified where the lines intersect this shim will 108
- Measure the clearance when engine is cold 2 check present shim size 3 match clearance in vertical column with present shim size in 108
- Remeasure the valve clearance and readjust if necessary 108
- Valve clearance adjustment chart exhaust valve 108
- Valves 108
- Caution 109
- Engine top end 4 21 109
- Valves 109
- 22 engine top end 110
- Valves 110
- Caution 111
- Engine top end 4 23 111
- Valves 111
- 24 engine top end 112
- Valves 112
- ______________________ caution______________________ 112
- Engine top end 4 25 113
- Valves 113
- Cylinder pistons 115
- Engine top end 4 27 115
- 28 engine top end 116
- Caution 116
- Cylinder pistons 116
- Cylinder pistons 117
- Engine top end 4 29 117
- 30 engine top end 118
- Cylinder pistons 118
- Carburetor holder 119
- Engine top end 4 31 119
- 32 engine top end 120
- Muffler 120
- Warning 120
- Engine top end 4 33 121
- Muffler 121
- Clutch 123
- Clutch 5 1 123
- Table of contents 123
- 2 clutch 124
- Exploded view 124
- Clutch 5 3 125
- Specifications 125
- 4 clutch 126
- Clutch lever and cable 126
- Clutch lever and cable 127
- _______________________________________________ ________ clutch 5 5 127
- 6 clutch 128
- Caution 128
- Clutch cover 128
- Clutch 129
- Clutch 5 7 129
- 8 clutch 130
- Caution 130
- Clutch 130
- Apply molybdenum disulfide grease to the pusher end a and install 131
- Clutch 131
- Clutch 5 9 131
- Clutch plate assembly adjustment 131
- Clutch plate assembly inspection inspect the friction plate thickness see clutch plate wear damage 131
- If the length is not within the specified range adjust the length see 131
- Inspection 131
- Install the clutch cover see clutch cover installation 131
- Install the clutch spring plate and spring and tighten the clutch spring 131
- Measure the length a of the clutch plate assembly as shown 0 assemble 131
- The bearing b pusher c spring d and washer e in the clutch spring plate fj 131
- 10 clutch 132
- Clutch 132
- Engine lube system 133
- Engine lubrication system 133
- Engine lubrication system 6 1 133
- Table of contents 133
- 2 engine lubrication system 134
- Exploded view 134
- Engine lubrication system 6 3 135
- Engine oil flow chart 135
- 4 engine lubrication system 136
- Specifications 136
- A warning 137
- Caution 137
- Engine lubrication system 6 5 137
- Engine oil and oil filter 137
- 6 engine lubrication system 138
- Engine oil and oil filter 138
- Engine lubrication system 6 7 139
- Oil cooler 139
- 8 engine lubrication system 140
- Oil pan 140
- Engine lubrication system 6 9 141
- Oil pump oil pump drive gear 141
- 10 engine lubrication system 142
- Oil pump oil pump drive gear 142
- Engine lubrication system 6 11 143
- Oil pressure measurement 143
- 12 engine lubrication system 144
- Oil pressure switch 144
- Engine removal installation 145
- Engine removal installation 7 1 145
- Engine removal lnstallation 145
- Table of contents 145
- 2 engine removal installation 146
- Exploded view 146
- Specifications 147
- ________________________________engine removal installation 7 3 147
- 4 engine removal installation 148
- Engine removal lnstallation 148
- Warning 148
- Engine removal installation 7 5 149
- Engine removal lnstallation 149
- 6 engine removal installation 150
- Engine removal lnstallation 150
- Crankshaft i transmission 151
- Crankshaft transmission 151
- Crankshaft transmission 8 1 151
- Table of contents 151
- 2 crankshaft transmission 152
- Exploded view 152
- Crankshaft transmission 8 3 153
- Exploded view 153
- 4 crankshaft transmission 154
- Specifications 154
- Crankshaft transmission 8 5 155
- Specifications 155
- 6 crankshaft transmission 156
- Crankcase splitting 156
- Caution 157
- Crankcase splitting 157
- Crankshaft transmission 8 7 157
- 8 crankshaft transmission 158
- Crankcase splitting 158
- Caution 159
- Crankshaft and connecting rods 159
- Crankshaft transmission 8 9 159
- 10 crankshaft transmission 160
- Crankshaft and connecting rods 160
- Warning 160
- Crankshaft and connecting rods 161
- Crankshaft transmission 8 11 161
- 12 crankshaft transmission 162
- Crankshaft and connecting rods 162
- Caution 163
- Crankshaft and connecting rods 163
- Crankshaft transmission 8 13 163
- 14 crankshaft transmission 164
- Crankshaft and connecting rods 164
- Crankshaft runout measure the crankshaft runout 164
- If the measurement exceeds the service limit replace the crankshaft 164
- Crankshaft transmission 8 15 165
- Transmission 165
- 16 crankshaft transmission 166
- Transmission 166
- Crankshaft transmission 8 17 167
- Transmission 167
- 18 crankshaft transmission 168
- Caution 168
- Transmission 168
- Crankshaft transmission 8 19 169
- Transmission 169
- 20 crankshaft transmission 170
- Transmission 170
- Crankshaft transmission 8 21 171
- Transmission 171
- Table of contents 173
- Wheels tires 173
- Wheels tires 9 1 173
- 2 wheels tires 174
- Exploded view 174
- Specifications 175
- Wheels tires 9 3 175
- 4 wheels tires 176
- Warning 176
- Wheels rims 176
- Warning 177
- Wheels rims 177
- Wheels tires 9 5 177
- 6 wheels tires 178
- A warning 178
- Wheels rims 178
- Caution 179
- Wheels rims 179
- Wheels tires 9 7 179
- Àwarning 179
- 8 wheels tires 180
- B installation completed 180
- Both sides of rim flange as shown 180
- Install the balance weight on the rim g slip the weight on the rim flange by pushing or lightly hammering the 180
- Installing balance weight a press or lightly hammer the weight in 180
- O check that the blade and weight seat fully on the rim flange and that 180
- The clip is hooked over the rim ridge and reaches rim flat portion 180
- Weight in the direction shown in the figure 180
- Wheels rims 180
- When required total weight exceeds 20g install balance weight at 180
- Wheels tires 9 9 181
- 10 wheels tires 182
- Caution 182
- Warning 183
- Wheels tires 9 11 183
- 12 wheels tires 184
- Caution 184
- Hub bearing 184
- Final drive 185
- Final drive 10 1 185
- Table of contents 185
- 2 final drive 186
- Exploded view 186
- Final drive 10 3 187
- Specifications 187
- 4 final drive 188
- A warning 188
- Drive chain 188
- Drive chain 189
- Final drive 10 5 189
- 6 final drive 190
- Drive chain 190
- Final drive 10 7 191
- Sprocket coupling 191
- 8 final drive 192
- Caution 192
- Sprocket coupling 192
- Final drive 10 9 193
- Sprocket coupling 193
- 10 final drive 194
- Sprocket coupling 194
- Brakes 195
- Brakes 11 1 195
- Table of contents 195
- 2 brakes 196
- Exploded view 196
- 4 brakes 198
- Specifications 198
- Brake pedal 199
- Brakes 11 5 199
- 6 brakes 200
- Calipers 200
- Warning 200
- Brakes 11 7 201
- Calipers 201
- Warning 201
- 8 brakes 202
- Calipers 202
- Warning 202
- Brakes 11 9 203
- Calipers 203
- Caution 203
- 10 brakes 204
- Brake pads 204
- Warning 204
- Brake pads 205
- _____________________________________________________ brakes 11 11 205
- 12 brakes 206
- Master cylinder 206
- Brakes 11 13 207
- Caution 207
- Master cylinder 207
- 14 brakes______________ ___ ____________________________________ 208
- Caution 208
- Master cylinder _________________________________ 208
- Brake disc 209
- Brakes 11 15 209
- 16 brakes 210
- A warning 210
- Brake fluid 210
- Brake fluid 211
- Brakes 11 17 211
- 18 brakes 212
- Brake fluid 212
- Brake fluid 213
- Brakes 11 19 213
- Warning 213
- 20 brakes ___________________________ 214
- Brake hose_____________________________________ 214
- ___ caution 214
- Suspension 215
- Suspension 12 1 215
- Table of contents 215
- 2 suspension 216
- Exploded view 216
- Exploded view 218
- Suspension 12 3 218
- 4 suspension 219
- Specifications 219
- Front fork 220
- Suspension 12 5 220
- 6 suspension 221
- Front fork 221
- Warning 221
- Front fork 222
- Suspension 12 7 222
- 8 suspension 223
- Front fork 223
- Front fork 224
- Suspension 12 9 224
- 10 suspension 225
- Front fork 225
- Front fork 226
- Suspension 12 11 226
- 12 suspension 227
- Front fork 227
- Warning 227
- Absorber removal 228
- Adjuster a until you feel a click 228
- Be adjusted harder for high speed riding or riding with a passenger if the damping feels too soft or too stiff adjust it in accordance with the following table 228
- Compression damping force adjustment to adjust the compression damping force turn the compression 228
- Damping adjuster a on the gas reservoir until you feel a click 228
- H i i i h i i i i ii i h l 228
- If the damping feels too soft or too stiff adjust it 228
- Lb with no passenger and no accessories is the 10th click from the 1 st click of the fully clockwise position 228
- Lb with no passenger and no accessories is the 10th click from the 1st click of the fully clockwise position 228
- Loosen the locknut and turn out the adjusting nut to free the spring 228
- Measure the spring free length 228
- O the damping force can be left soft for average riding but it should 228
- O the standard adjuster setting for an average build rider of 68 kg 150 228
- Rear shock absorber 228
- Rebound damping force adjustment to adjust the rebound damping force turn the rebound damping 228
- Spring preload adjustment remove the rear shock absorber from the frame see rear shock 228
- Suspension 12 13 228
- The standard adjuster setting for the average build rider of 68 kg 150 228
- 14 suspension 229
- C spring length 229
- If the spring action feels too soft or too stiff adjust it 229
- Kg 150 lb with no passenger and no accessories is 180 mm spring length 229
- Lower shock absorber bolt a upper tie rod bolt b 229
- O the standard adjusting nut setting for an average build rider of 68 229
- Position and tighten the locknut b 229
- Rear shock absorber 229
- Rear shock absorber installation pack the rocker arm needle bearings with grease tighten the following nuts 229
- Rear shock absorber removal remove the lower fairings see frame chapter using the jack raise the rear wheel off the ground 229
- Remove 229
- Remove the shock absorber forward the ground 229
- To adjust the spring preload turn in the adjusting nut a to the desired 229
- Upper shock absorber bolt a 229
- Rear shock absorber 230
- Suspension 12 15 230
- Warning 230
- 16 suspension 231
- Swingarm 231
- Suspension 12 17 232
- Tie rod rocker arm 232
- Steering 234
- Steering 13 1 234
- Table of contents 234
- 2 steering 235
- Exploded view 235
- Specifications 236
- Steering 13 3 236
- 4 steering 237
- Steering 237
- Steering 13 5 238
- Steering stem 238
- 6 steering 239
- Steering stem 239
- Steering 13 7 240
- Steering stem 240
- Warning 240
- 8 steering 241
- Handlebar 241
- Handlebar 242
- Handlebar holder installation apply a non permanent locking agent to the thread of handlebar 242
- Install the remove parts see appropriate chapters 242
- Position bolts and tighten the them 242
- Steering 13 9 242
- Frame 14 1 244
- Table of contents 244
- 2 frame 245
- Exploded view 245
- 4 frame 247
- Exploded view 247
- Frame 14 5 248
- 6 frame 249
- Seat covers 249
- Fairings 250
- Frame 14 7 250
- 8 frame 251
- Fenders 251
- Frame 14 9 252
- Electrical system 254
- Table of contents 254
- ______________________________________electrical system 15 1 254
- 2 electrical system__________________________ ________________ 255
- Electrical system 15 3 256
- Exploded view 256
- 4 electrical system 257
- Exploded view 257
- Electrical system 15 5 258
- Exploded view 258
- Color code 260
- Electrical system 15 7 260
- Wiring diagram u s a and canada 260
- Electrical system 15 9 262
- 10 electrical system 263
- Wiring diagram other than u s a canada australia and malaysia 263
- Electrical system 15 11 264
- Wiring diagram other than u s a canada 264
- 14 electrical system 267
- Specifications___________________________________ 267
- Electrical system 15 15 268
- Parts location 268
- 16 electrical system 269
- Precautions 269
- Electrical system 15 17 270
- Electrical wiring 270
- 18 electrical system 271
- Battery 271
- Caution 271
- Battery 272
- Caution 272
- Electrical system 15 19 272
- _____________________ caution_______ 272
- 20 electrical system__________________________________________ battery 273
- Caution 273
- Battery 274
- Electrical system 15 21 274
- 22 electrical system 275
- Battery 275
- Charging system 276
- ___________________________________ electrical system 15 23 276
- 24 electrical system 277
- Chargin g system 277
- Charging system 278
- Electrical system 15 25 278
- 26 electrical system 279
- Charging system 279
- Caution 280
- Charging system 280
- Electrical system 15 27 280
- 28 electrical system 281
- Charging system 281
- __________________ caution___________________ 281
- Charging system 282
- Electrical system 15 29 282
- 30 electrical system 283
- Ignition system 283
- Warning 283
- Electrical system 15 31 284
- Ignition system 284
- 32 electrical system 285
- Caution 285
- Ignition system 285
- _____________________caution_____________________ 285
- Electrical system 15 33 286
- Ignition system 286
- Warning 286
- 34 electrical system 287
- Caution 287
- Ignition system 287
- Electrical system 15 35 288
- Ignition system 288
- 36 electrical system 289
- Caution 289
- Ignition system 289
- Electrical system 15 37 290
- 38 electrical system 291
- Ignition system 291
- Ignition system circuit 291
- Caution 292
- Electric starter system 292
- Electrical system 15 39 292
- 40 electrical system 293
- Electric starter system____________________________________________________________ 293
- Electric starter system 294
- Electrical system 15 41 294
- 42 electrical system 295
- Electric starter system 295
- Electric starter system 296
- Electrical system 15 43 296
- 44 electrical system 297
- Electric starter circuit 297
- Electric starter system 297
- Caution 298
- Electrical system 15 45 298
- Lighting system 298
- 46 electrical system 299
- Lighting system 299
- Electrical system 15 47 300
- Lighting system 300
- 48 electrical system 301
- Lighting system 301
- Electrical system 15 49 302
- Lighting system 302
- Turn signal light circuit 302
- 50 electrical system 303
- Caution 303
- Fuel pump 303
- Electrical system 15 51 304
- Fuel pump 304
- Fuel pump circuit 304
- 52 electrical system 305
- A warning 305
- Fuel cut valve 305
- Electrical system 15 53 306
- Fuel cut valve 306
- Fuel cut valve circuit 306
- 54 electrical system 307
- Radiator fan circuit 307
- Radiator fan system 307
- Electrical system 15 55 308
- 56 electrical system 309
- Caution 309
- Caution 310
- Electrical system 15 57 310
- 58 electrical system 311
- Electrical system 15 59 312
- 60 electrical system 313
- Meter circuit 313
- Caution 314
- Electrical system 15 61 314
- Switches and sensors 314
- 62 electrical system 315
- Caution 315
- Switches and sensors 315
- Caution 316
- Electrical system 15 63 316
- Switches and sensors 316
- 64 electrical system 317
- And diodes can not be removed 317
- Apply tester positive lead apply tester negative lead 317
- Clean the dirty terminals and straighten slightly bent terminals check conductivity of the numbered terminals with the hand tester 317
- If the tester does not read as specified replace the junction box 317
- Junction box 317
- Junction box fuse circuit inspection remove the seats see frame chapter remove the junction box pull off the connectors from the junction box make sure all connector terminals are clean and tight and none of 317
- Starter circuit headlight relay inspection remove the junction box check conductivity of the following numbered terminals by connecting 317
- The hand tester and one 12 v battery to the junction box as shown 317
- The junction box a has fuses b relays and diodes the relays 317
- Them have been bent 317
- U s a canada australia and malaysia models only the actual reading varies with the hand tester used 317
- Electrical system 15 65 318
- Junction box 318
- 66 electrical system 319
- Junction box 319
- Caution 320
- Electrical system 15 67 320
- Appendix 322
- Appendix 16 1 322
- Table of contents 322
- 2 appendix_____________ 323
- Additional considerations for racing 323
- Carburetor 323
- Spark plug 323
- Additional considerations for racing 324
- Appendix 16 3 324
- 4 appendix_____________ 325
- Additional considerations for racing 325
- Caution 325
- Appendix 16 5 326
- Engine doesn t start starting difficulty 326
- Poor running at low speed 326
- Troubleshooting guide 326
- 6 appendix 327
- Overheating 327
- Poor running or no power at high speed 327
- Troubleshooting guide 327
- Abnormal drive train noise 328
- Abnormal engine noise 328
- Abnormal frame noise 328
- Appendix 16 7 328
- Clutch operation faulty 328
- Gear shifting faulty 328
- Over cooling 328
- Troubleshooting guide 328
- 8 appendix 329
- Battery trouble 329
- Brake doesn t hold 329
- Exhaust smokes excessively 329
- Handling and or stability unsatisfactory 329
- Oil pressure warning light goes on 329
- Troubleshooting guide 329
- Appendix 16 9 330
- General lubrication 330
- 10 appendix__________ 331
- Nut bolt and fastener tightness 331
- Appendix 16 11 332
- Prefixes for units units of length 332
- Unit conversion table 332
- Units of force 332
- Units of mass 332
- Units of power 332
- Units of pressure 332
- Units of speed 332
- Units of temperature 332
- Units of torque 332
- Units of volume 332
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11 8 BRAKES Calipers Replace the fluid seals A with new ones 0 Apply brake fluid to the fluid seals and install them into the cylinders by hand Replace the dust seals B with new ones if they are damaged O Apply brake fluid to the dust seals and install them into the cylinders by hand Replace the O rings A if they are damaged Apply brake fluid to the outside of the pistons and push them into each cylinder by hand Be sure to install the O rings Tighten the caliper assembly bolts Torque Front Caliper Assembly Bolts 21 N m 2 1 kg m 15 0 ft lb Install the pads see Front Brake Pad Installation Wipe up any spilled brake fluid on the caliper with wet cloth Rear Caliper Disassembly Remove the rear caliper Remove the pads and anti rattle spring see Rear Brake Pad Re moval Remove the piston insulator Using compressed air remove the piston O Cover the caliper opening with a clean heavy cloth A 0 Remove the piston by lightly applying compressed air B to where the brake line fits into the caliper AWARNING To avoid serious injury never place your fingers or palm inside the caliper opening If you apply compressed air into the caliper the piston may crush your hand or fingers Remove the dust seal and fluid seal Remove the bleed valve and rubber cap NOTE If compressed air is not available do as follows with the brake hose connected to the caliper Prepare a container for brake fluid and perform the work above it 0 Remove the pads and spring see Rear Brake Pad Removal 0 Pump the brake pedal to remove the caliper piston 2
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