Kawasaki Z1000SX - Service manual > Brake Disc

Brakes / Brake Disc

Brake Disc Removal

  • Remove the wheels (see Front/Rear Wheel Removal in the Wheels/Tires chapter).
  • Unscrew the mounting bolts [A], and take off the disc [B].
  • Remove the gaskets.

Brake Disc

Brake Disc Installation

  • Replace the gaskets with new ones.
  • Install the brake disc on the wheel so that the marked side [A] faces out.
  • Apply a non-permanent locking agent to the threads of the front and rear brake disc mounting bolts, and tighten them.

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

Brake Disc

Brake Disc Wear

  • Measure the thickness of each disc [A] at the point where it has worn the most.

    If the disc has worn past the service limit, replace it.

    Measuring Area [B]

Brake Discs Thickness
  Front 5.3 - 5.7 mm (0.21 - 0.22 in.)
  Rear 5.8 - 6.2 mm (0.23 - 0.24 in.)
 Service Limit:
  Front 5.0 mm (0.20 in.)
  Rear 5.5 mm (0.22 in.)

Brake Disc

Brake Disc Warp

  • Raise the front/rear wheel off the ground.

    Special Tools - Jack: 57001-1238
     Attachment Jack: 57001-1252
     Jack Attachment: 57001-1608

    • For front disc inspection, turn the handlebar fully to one side.
  • Set up a dial gauge against the disc [A] as shown in the figure and measure disc runout, while turning [B] the wheel by hand.

If runout exceeds the service limit, replace the disc.

Disc Runout
 Standard: TIR 0.15 mm (0.006 in.) or less
 Service Limit: TIR 0.3 mm (0.01 in.)

Brake Disc

    See also:

     Kawasaki Z1000SX - Service manual > Master Cylinder

    Front Master Cylinder Removal Remove the rear view mirror (see Rear View Mirror Removal in the Frame chapter). Remove the banjo bolt [A] to disconnect the brake hose from the master cylinder (see Brake Hose Removal/Installation). Unscrew the clamp bolts [B], and take off themaster cylinder [C] as an assembly with the reservoir, brake lever, and brake switch installed. Disconnect the front brake light switch connector [D].

     Kawasaki Z1000SX - Service manual > Brake Fluid

    Brake Fluid Level Inspection Refer to the Brake Fluid Level Inspection in the Periodic Maintenance chapter. Brake Fluid Change Refer to the Brake Fluid Change in the Periodic Maintenance chapter.