NOTE

○Wheel alignment can be also checked using the
straightedge or string method.
WARNING
Misalignment of the wheel will result in abnormal
wear and may result in an unsafe riding condition.
Be sure the wheel is properly aligned.

Drive Chain Wear Inspection

the chain cover (see Drive Chain Removal/In• Remove
stallation in the Final Drive chapter).
the rear wheel to inspect the drive chain for dam• Rotate
aged rollers, and loose pins and links.

•
•

If there is any irregularity, replace the drive chain.
Lubricate the drive chain if it appears dry.
Stretch the chain taut by hanging a 10 kg (22 lb) weight
[A] on the chain.
Measure the length of 20 links [B] on the straight part [C] of
the chain from the pin center of the 1st pin to the pin center
of the 21st pin. Since the chain may wear unevenly, take
measurements at several places.
If any measurements exceed the service limit, replace the
chain. Also, replace the front and rear sprockets when the
drive chain is replaced.
Drive Chain 20-link Length
Standard:
317.5  318.2 mm (12.50  12.53 in.)
Service Limit: 319 mm (12.6 in.)

WARNING
A chain that breaks or jumps off the sprockets
could snag on the engine sprocket or lock the
rear wheel, severely damaging the motorcycle and
causing it to go out of control. Inspect the chain for
damage and proper adjustment before each ride.
If chain wear exceeds the service limit, replace it
with the standard chain.
Standard Chain
Make:
ENUMA
Type:

EK525RMX3/3D

Link:

114 links

2-42 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Chain Guide Wear Inspection

the swingarm (see Swingarm Removal in the
• Remove
Suspension chapter).
inspect the chain guide [A].
• Visually
Replace the chain guide if it shows any signs of abnormal
wear or damage.

PERIODIC MAINTENANCE 2-43
Periodic Maintenance Procedures
Brakes
Brake System Inspection
Brake Fluid Leak (Brake Hose and Pipe) Inspection
For ZX1000S/Z, remove the following parts:
Fuel Tank (see Fuel Tank Removal in the Fuel System
(DFI) chapter)
ABS Hydraulic Unit Cover (see ABS Hydraulic Unit Removal in the Brakes chapter)
Apply the brake lever or pedal and inspect the brake fluid
leak from the brake hoses [A], fittings [B] and brake pipes.
If the brake fluid leaked from any position, inspect or replace the problem part.

•
•

2-44 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Brake Hose and Pipe Damage and Installation Condition Inspection
For ZX1000S/Z, remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter).
Inspect the brake hoses, pipes 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, pipe to burst if the line is not properly
maintained. Bend and twist the rubber hose while examining it.
Replace the hose and pipe if any crack [B], bulge [C] or
leakage is noticed.
Tighten any brake hose banjo bolts and brake pipe joint
nuts.

•
•

Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
Brake Pipe Joint Nuts: 18 N·m (1.8 kgf·m, 13 ft·lb)

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

Brake Operation Inspection

the operation of the front and rear brake by run• Inspect
ning 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

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

NOTE

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

•

If the fluid level is lower than the MIN level line, fill the
reservoir to the MAX level line [C].
Tighten:
Torque - Front Brake Fluid Reservoir Cap Screws: 0.70 N·m
(0.07 kgf·m, 6.2 in·lb)

PERIODIC MAINTENANCE 2-45
Periodic Maintenance Procedures
that the brake fluid level in the rear brake reservoir
• Check
[A] is above the lower level line [B].
If the fluid level is lower than the lower level line, fill the
reservoir to the upper level line [C].
○Remove the stopper [D].

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:
DOT4

the procedure below to install the rear brake fluid
• Follow
reservoir cap correctly.

○First, tighten the brake fluid reservoir cap [A] clockwise

•

[B] by hand until slight resistance is felt indicating that the
cap is seated on the reservoir body [C], then tighten the
cap an additional 1/6 turn [D] while holding the brake fluid
reservoir body.
Install the stopper and tighten its bolt.

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.
the brake fluid reservoir.
• Level
the reservoir cap, diaphragm plate and di• Remove
aphragm.
the rubber cap from the bleed valve on the
• Remove
caliper.
a wrench [A] and a clear plastic hose [B] to the
• Attach
bleed valve, and run the other end of the hose into a con-

•

tainer.
Fill the reservoir with fresh specified brake fluid.

2-46 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the brake fluid.
•○Change
Repeat this operation until fresh brake fluid comes out
1.
2.
3.
4.

from the plastic hose or the color of the fluid changes.
Open the bleed valve [A].
Apply the brake and hold it [B].
Close the bleed valve [C].
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.
○Front Brake: Repeat the above steps for the other
caliper.
the clear plastic hose.
• Remove
Install
the
• Tighten: diaphragm, diaphragm plate and reservoir cap.
•
Torque - Front Brake Reservoir Cap Screws: 0.70 N·m (0.07
kgf·m, 6.2 in·lb)

the procedure below to install the rear brake fluid
• Follow
reservoir cap correctly.

○First, tighten the rear brake fluid reservoir cap [A] clock-

•

wise [B] by hand until slight resistance is felt indicating
that the cap is seated on the reservoir body [C], then
tighten the cap an additional 1/6 turn [D] while holding the
brake fluid reservoir body.
Install the reservoir cap stopper, and tighten its bolt.

• Tighten the bleed valve, and install the rubber cap.
Torque - Front Caliper Bleed Valves: 16 N·m (1.6 kgf·m, 12
in·lb)
Rear Caliper Bleed Valve: 8.0 N·m (0.82 kgf·m, 71
in·lb)

changing the fluid, check the brake for good braking
• After
power, no brake drag, and no fluid leakage.
If necessary, bleed the air from the lines.

PERIODIC MAINTENANCE 2-47
Periodic Maintenance Procedures
Brake Hose and Pipe Replacement
NOTICE
Brake fluid quickly damages painted plastic surfaces; any spilled fluid should be completely
washed away immediately.

• Remove:
Brake Hose Fitting Bolt [A]
Brake Hose Banjo Bolts [B]
Mud Guard [C] (see Mud Guard Removal in the Frame
chapter)
When removing the brake hoses [D], 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: 25 N·m (2.5 kgf·m, 18
ft·lb)

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

2-48 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
ZX1000S/Z; note the following.
• For
Viewed from Bottom [A]

NOTE

○When removing the brake pipes and hoses on the hydraulic unit, remove them with a flare nut wrench according to each assembly of the exploded view in the
Brakes chapter.

• Remove:
Throttle Body Assy (see Throttle Body Assy Removal in

•

the Fuel System (DFI) chapter)
Upper Fairing Assembly (see Upper Fairing Assembly
Removal in the Frame chapter)
Rear Fender (see Rear Fender Removal in the Frame
chapter)
Rear Shock Absorber (see Rear Shock Absorber Removal in the Suspension chapter)
Swingarm (see Swingarm Removal in the Suspension
chapter)
Rocker Arm (see Rocker Arm Removal in the Suspension chapter)
Steering Damper Mounting Bracket [B]
Brake Pipe Joint Nuts [C]
Brake Hose Banjo Bolts [D]
Bolts [E]
Clamps [F]
Grommet [G]
Band [H]
Before installing the brake pipe, check to see that there is
no damage on the threads of the brake pipe joint nut.
If there is any damage, replace the damaged parts with
new ones.

NOTE

○Tighten the brake pipe joint nut at both ends of the brake
pipe temporarily and then tighten them to the specified
torque.
the brake pipes and brake hoses to the specified
• Install
angle (see Cable, Wire, and Hose Routing section in the

•
•

Appendix chapter).
Tighten the brake pipe joint nuts with the flare nut wrench.
Tighten:
Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
Brake Pipe Joint Nuts: 18 N·m (1.8 kgf·m, 13 ft·lb)

NOTE

○The thread pitch of the front brake banjo bolts differ from
the rear ones. Check the thread pitch before installing.

PERIODIC MAINTENANCE 2-49
Periodic Maintenance Procedures

2-50 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Master Cylinder Rubber Parts Replacement
Front Master Cylinder Disassembly
Remove the front master cylinder (see Front Master Cylinder Removal in the Brakes chapter).
Replace the replacement parts as an assembly of the
front master cylinder.

•
•

Rear Master Cylinder Disassembly
Remove the rear master cylinder (see Rear Master Cylinder Removal in the Brakes chapter).
Remove the circlip [A], connector [B] and O-ring [C].

•
•

Special Tool - Inside Circlip Pliers: 57001-143

the dust cover [D] out of place, and remove the cir• Slide
clip [E].
out the push rod assembly [F].
• Pull
Remove
the piston assembly [G] and return spring [H].
•

NOTICE
Do not remove the secondary cup from the piston
since removal will damage it.

• Replace:
Circlip [A]
O-ring [C]
Circlip [E]
Push Rod Assembly [F]
Piston Assembly [G]
Diaphragm [I]
Rear Master Cylinder Assembly
Before assembly, clean all parts including the master
cylinder with brake fluid or alcohol.

•

NOTICE
Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning brake parts. Do not use any other fluid for
cleaning these parts. Gasoline, engine oil, or any
other petroleum distillate will cause deterioration of
the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the disc brake.
brake fluid to the new parts and to the inner wall of
• Apply
the cylinder.
care not to scratch the piston or the inner wall of the
• Take
cylinder.
silicone grease to the dust cover of the push rod
• Apply
assembly.
• Assemble the rear master cylinder.

Caliper Rubber Parts Replacement
Front Caliper Disassembly
Remove:
Front Caliper (see Front Caliper Removal in the Brakes
chapter)
Brake Pads (see Front Brake Pad Removal in the Brakes
chapter)

•

PERIODIC MAINTENANCE 2-51
Periodic Maintenance Procedures
the pistons nearest the oil passage [A] with the
• Hold
bands [B].

compressed air, remove the pistons.
•○Using
Cover the caliper opening with a clean heavy cloth [A].

○Lightly apply compressed air [B] to the oil passage.
WARNING

The piston in the brake caliper can crush hands and
fingers. Never place your hand or fingers in front of
the piston.

○Pull out the pistons by hand.
compressed air is not used, using the brake caliper
• When
piston pliers [A] remove the pistons [B].
Special Tool - Brake Caliper Piston Pliers ( 16 
57001-1861

26):

the fluid seals [A] and dust seals [B].
• Remove
the bands.
• Cut
Repeat
step to remove the pistons from the
• other sidetheofprevious
the caliper body.
• Remove the bleed valve and rubber cap.

Front Caliper Assembly
Clean the caliper parts except for the pads.

•

NOTICE
For cleaning the parts, use only disc brake fluid,
isopropyl alcohol, or ethyl alcohol.
the bleed valve and rubber cap.
• Install
Tighten:
•
Torque - Front Caliper Bleed Valves: 16 N·m (1.6 kgf·m, 12
ft·lb)

2-52 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the fluid seals [A] with new ones.
•○Replace
Apply silicone grease to the fluid seals, and install them
into the cylinders by hand.
Replace the dust seals [B] with new ones if they are damaged.
○Apply silicone grease to the dust seals, and install them
into the cylinders by hand.

•

brake fluid to the outside of the pistons, and push
• Apply
them into each cylinder by hand.
the removed parts (see appropriate chapters).
• Install
Wipe
up
• cloth. any spilled brake fluid on the caliper with wet
Rear Caliper Disassembly
Remove:
Rear Caliper (see Rear Caliper Removal in the Brakes
chapter)
Brake Pads (see Rear Brake Pad Removal in the Brakes
chapter)
Bolt [A]
Caliper Bracket [B]

•

• Remove:
Pad Spring [A]
Dust Boot [B]

compressed air, remove the piston.
•○Using
Cover the caliper opening with a clean, heavy cloth [A].

○Remove the piston by lightly applying compressed air [B]
to where the brake line fits into the caliper.

WARNING
The piston in the brake caliper can crush hands and
fingers. Never place your hand or fingers in front of
the piston.

PERIODIC MAINTENANCE 2-53
Periodic Maintenance Procedures
compressed air is not used, using the brake caliper
• When
piston pliers [A] remove the piston [B].
Special Tool - Brake Caliper Piston Pliers ( 16 
57001-1861

26):

the dust seal and fluid seal.
• Remove
Remove
the
bleed valve and rubber cap.
•
Rear Caliper Assembly
Clean the caliper parts except for the pads.

•

NOTICE
For cleaning the parts, use only disc brake fluid,
isopropyl alcohol, or ethyl alcohol.

• Install the bleed valve and rubber cap.
Torque - Rear Caliper Bleed Valve: 8.0 N·m (0.82 kgf·m, 71
in·lb)

the fluid seal [A] with a new one.
•○Replace
Apply silicone grease to the fluid seal, and install it into
the cylinder by hand.
Replace the dust seal [B] with a new one.
○Apply silicone grease to the dust seal, and install it into
the cylinder by hand.

•

the pad spring [A] in the caliper as shown.
• Install
Apply
brake
fluid to the outside of the piston [B], and push
• it into the cylinder
by hand.
Replace
the
and
dust
boot [C].
•

2-54 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
the pad spring [A] on the caliper bracket as shown.
• Install
Apply
a
grease to the caliper bracket shaft [B].
• Replacesilicone
boot [C].
• Assemblethethefriction
caliper
the caliper bracket.
• Apply silicone grease and
to
the
rear caliper pin bolt.
• Tighten:
•
Torque - Rear Caliper Pin Bolt: 27 N·m (2.8 kgf·m, 20 ft·lb)

the pads (see Rear Brake Pad Installation in the
• Install
Brakes chapter).