Kawasaki J300 - Service manual > Brake System

Brake Fluid Leak Inspection

• For ABS equipped model, remove the front fairing (see Front Fairing Removal in the Frame chapter).
• Apply the brake lever and inspect the brake fluid leak from the brake hoses [A] and fittings [B].

  If the brake fluid leaked from any position, inspect or replace the problem part.

  ABS equipped model [C]

Brake Hose Installation Condition Inspection

• For ABS equipped model, remove the front fairing (see Front Fairing Removal in the Frame chapter).
• Inspect the brake hoses and fittings for deterioration, cracks and signs of leakage.
  • The high pressure inside the brake line can cause fluid to leak [A] or the hose to burst if the line is not properly maintained.

    Bend and twist the rubber hose while examining it.

Replace the hose if any crack [B], bulge [C] or leakage is noticed.

• Tighten any brake hose banjo bolts.

  Torque - Brake Hose Banjo Bolts: 34 N*m (3.5 kgf*m, 25 ft*lb)

• Inspect the brake hose routing.

  If any brake hose routing is incorrect, run the brake hose according to Cable, Wire, and Hose Routing section in the Appendix chapter.

Brake Operation Inspection

• Inspect the operation of the front and rear brake by running the vehicle on the dry road.

  If the brake operation is insufficiency, inspect the brake system.

WARNING When test riding the vehicle, be aware of surrounding traffic for your safety.

Brake Fluid Level Inspection

• Check that the brake fluid level in the brake reservoir [A] is above the lower level line [B].

NOTE

• Hold the reservoir horizontal by turning the handlebar when checking the brake fluid level.

If the fluid level is lower than the lower level line, fill the reservoir to the upper level line [A].

• Remove the reservoir cap and diaphragm.

WARNING Mixing brands and types of brake fluid can reduce the brake system's effectiveness and cause an accident resulting in injury or death. Do not mix two brands of brake fluid. Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are unidentified.

Recommended Disc Brake Fluid
 Grade: DOT

Brake Fluid Change

NOTE

• The procedure to change the front brake fluid is as follows.

  Changing the rear brake fluid is the same as for the front brake.

 

• Level the brake fluid reservoir.
• Remove the reservoir cap and diaphragm.
• Remove the rubber cap [A] from the bleed valve on the caliper.
• Attach a clear plastic hose [B] to the bleed valve, and run the other end of the hose into a container.
• Fill the reservoir with fresh specified brake fluid.

• Change the brake fluid.
  • Repeat this operation until fresh brake fluid comes out from the plastic hose or the color of the fluid changes.

1. Open the bleed valve [A].
2. Apply the brake and hold it [B].
3. Close the bleed valve [C].
4. Release the brake [D].

NOTE

• The fluid level must be checked often during the changing operation and replenished with fresh brake fluid. If the fluid in the reservoir runs out any time during the changing operation, the brakes will need to be bled since air will have entered the brake line.

 

• Remove the clear plastic hose.
• Install the diaphragm and reservoir cap.

  Torque - Brake Reservoir Cap Screws: 1.6 N*m (0.16 kgf*m, 14 in*lb)

• Tighten the bleed valve, and install the rubber cap.

  Torque - Bleed Valves: 5.4 N*m (0.55 kgf*m, 48 in*lb)

• After changing the fluid, check the brake for good braking power, no brake drag, and no fluid leakage.

  If necessary, bleed the air from the lines.

Brake Hose Replacement

NOTICE Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately.

• Remove:
  Upper Handlebar Cover (see Handlebar Cover Removal in the Frame chapter)
  Leg Shield (see Leg Shield Removal in the Frame chapter)
  Brake Hose Clamps [A]
  Brake Hose Banjo Bolts [B]
  Bands (see Cable, Wire, and Hose Routing section in the Appendix chapter)

• When removing the brake hoses [C], note the following.
  • Take care not to spill the brake fluid on the painted or plastic parts.
  • Temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum.
  • Immediately wash away any brake fluid that spills.

• When installing the brake hoses, note the following.
  • Avoid sharp bending, kinking, flatting or twisting, and run the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter.
  • There are washers on each side of the brake hose fitting.

    Replace them with new ones.

  • Tighten:

Torque - Brake Hose Banjo Bolts: 34 N*m (3.5 kgf*m, 25 ft*lb)

• Fill the brake line after installing the brake hose (see Brake Fluid Change).

  ABS equipped model [D]

See also: