Kawasaki KLE500 (2004) [263/401] Brakes 12 17
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Kawasaki KLE500 (2004) [263/401] Brakes 12 17

Kawasaki KLE500 (2004) [263/401] Brakes 12 17
BRAKES 12-17
Master Cylinder
Front Master Cylinder Removal
•
Disconnect the front brake switch connectors [A].
•
Remove the banjo bolt [B] to disconnect the upper brake
hose end from the master cylinder [C]. There is a flat
washer on each side of the hose fitting.
•
Remove the clamp bolts [D] and take off the master cylin-
der as an assembly with the reservoir, brake lever, and
brake switch installed.
CAUTION
Immediately wipe up any brake fluid that spills.
Front M aster Cylinder Installation
•
Apply grease to the extreme end of the clamp bolts.
•
Install the master cylinder clamp so that the upper mating
surface [A] of the clamp is aligned with the punch m ark
[B] on the handlebar.
•
Tighten the upper clamp bolt first, and then the lower
clamp bolt. There will be a gap at the lower part of the
clamp after tightening.
Torque - Master Cylinder C la mp Bolts: 8.8 N·m (0.9 kgf·m,
78 in·lb)
•
Use a new flat washer on each side of the brake hose
fitting.
•
Tighten the banjo bolt.
Torque - Brake Hose Banjo Bolt: 34 N·m (3.5 kgf·m, 25 ft·lb)
•
Bleed the brake line after master cylinder installation (see
Bleeding the Brake Line).
•
Check the brake for weak braking power, brake drag, and
fluid leakage.
WARNING
Do not attempt to drive the motorcycle until a full
brake lever is obtained by pumping the brake lever
until the pads are against the disc. The brake will
not function on the first application of the lever if
this is not done.
Rear Master Cylinder Removal
•
Remove the right side cover.
•
Remove the muffler cover bolts [A] and muffler cover [B].

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