PROJECT H2 WorkShop: Kawasaki ファクトリデータ

H シリーズ ダブルディスク・コンバージョンキット・マニュアル

Last update: 2008-12-28

ダブルディスク・コンバージョンキット・マニュアルについて

H Series Dual Disk Conversion Kit Manual は1972年から発売された H シリーズ用オプションパーツのダブルディス・クコンバージョンキットに付属していた、北米カワサキディラー向けマニュアルである。
マニュアルの原本を譲ってくれた、元カワサキディーラーの方によると、このマニュアルはダブルディスクコンバージョンキットに付属していたそうだ。ただし、このマニュアルが一般ユーザに配られたかどうかについては確認できなかった。
私が記憶している限り、日本にはコンバージョンキットとしては販売されていなかったと思う。当時を知っている私の先輩の話でも H2 や H1 オーナーにはダブルディスクに変更するパーツが用意されているとだけ口頭で知らされ、公な資料は見たことが無いと言っていた。もしかすると販売店向けにマニュアルが存在したのかもしれないが、私は現在まで確認していない。
アメリカに存在するその他のマニュアルに言えることだが、公式に発行された情報と資料の数は日本よりもはるかに多かったことが伺える。

今のところ翻訳する時間がないので、このページでは原文のままで公開するが、時間をとることができれば和訳して再度アップします。

Tools and Supplies Required: [P1]

  • Wrenches
    • 10 mm
    • 12 mm
    • 13 mm
    • 14 mm
    • 17 mm
    • 19 mm
  • Common screwdriver
  • Phillips screwdriver, No. 2
  • Common pliers
  • Clean cloth
  • Clear plastic hose
  • Brake fluid
  • Rubbing alcohol
  • Wooden box
  • Container, 1 quart capacity
  • Parts List:

The following parts should be included in your dual disc brake conversion: [P1]

Description Part Number Qty
Master cylinder assembly [1] 43015-002 1
Joint fitting, four-way [2] 43075-001 1
Washers, plain 6mm [3] 410B0600 50
Washers, spring 6mm [4] 461F0600 50
Bolts, hex head,6 × 32 [5] 110N0632 10
Washers, oil bolt [6] 43067-001 10
Bolts, oil [7] 43066-001 5
Hose, front brake [8] 43059-002 1
Pipe, front brake RH [9] 43060-002 1
Rubber damper, brake hose [10] 43064-001 5
Hose bracket [11] 43063-003 1
Caliper brake assembly [12] 43041-002 1
Washers, plain, 10mm [13] 410B1000 10
Washers, spring, 10mm [14] 461F1000 10
Bolt, hex head, 10 × 48 [45] 43070-001 5
Disc plate [16] 41080-001 1
Washers, lock, 8mm [17] 92088-014 5
Bolts, hex head, 8 x28 [18] 92001-104 10

REMOVE FRONT WHEEL [P2]

  1. Disconnect speedometer cable [4] from speedometer drive gear assembly [3]
  2. Place wooden box under engine to raise front wheel off ground. In next step, wheel must be supported while remove right and left mounting caps [2]
  3. Remove left and light 13mm nuts [1] and washers. Remove mounting caps [2]. Remove wheel.

REMOVE AND INSTALL JOINT FITTING: [P2]

Remove Joint Fitting.
CAUTION: If brake fluid is spilled, it must be cleaned immediately from chromed, painted or rubber parts to prevent damage to these parts.

  1. Place container under joint fitting [3]. Disconnect front brake hose [5] by removing 14mm oil bolt [4] and washers. Allow brake fluid to drain completely.
  2. Disconnect two electrical wires [7] on stop light switch [8].
  3. Remove 14mm oil bolt [1] and washers.
  4. Using vise grip pliers, carefully remove stop light switch [8].
  5. Remove two 10mm bolts [2] and washers. Remove joint fitting [3] and hose bracket [6]. Discard hose bracket.

REMOVE AND INSTALL JOINT FITTING: [P3]

Install Four-Way Joint Fitting.

  1. Install stop light switch [6] in Four-Way joint fitting [8], fingertight.
  2. Place washer and hose [5] at installed position. Install 14mm oil bolt [2] and washer. See Torque Value Chart on last page.
  3. Install spring washer [9] and plain washer on two 10mm bolts [10].
  4. Place Four-Way joint fitting [8] at installed position. Install two bolts [10]. See Torque Value Chart on last page.
  5. Tighten stop light switch [6]. Connect two electrical wires [11]. Brake hose bracket [1] should be installed between fender brace [3] and fork leg [7].
  6. Remove two 13mm bolts [4] and washers.
  7. Place and hold hose bracket [1] at installed position. Install two 13mm bolts [4] and washers. See Torque Value Chart on last page.

REMOVE AND INSTALL MASTER CYLINDER: [P4]

Remove Master Cylinder

  1. Remove rear view mirror, if installed.
  2. Slide rubber boot [7] down hose [8]. Remove 14mm oil bolt [6] and washers.
  3. While holding master cylinder [4], remove two 10mm bolts [1] and washers. Remove holder [3]. Remove and discard master cylinder.

INSTALL MASTER CYLINDER: [P4]

WARNING
Be sure master cylinder Part Number 43015-002 is used. Old master cylinder must be not be used. Cylinder's capacity is insufficient to safely operate both caliper brakes.

  1. Place new master cylinder [4] at installed position. Install holder [3] with tab [2] facing to rear. install two 10mm bolts [1] and washers. See Torque Value Chart on last page.
  2. Place washer and brake hose {8] at installed position. Install oil bolt [6] and washer.
  3. Slide rubber boot [7] over outlet [5].

INSTALL BRAKE DISC PLATE:: [P5]

CAUTION
When removing speedometer drive gear assembly [5], be careful not to drop drive gear [6].

  1. While holding 19mm axle [1]. remove 19mm speedometer drive gear assembly [5] by turning counterclockwise.
  2. Remove axle [1] from hub [7]
  3. Remove three screws [3]. Remove cover plate [2]
  4. Place brake disc plate [4] at installed position. Install six 12mm bolts [9] and lock tab washer [8]. See Torque Value Chart on last page.
  5. Using hammer and common screwdriver, bend lock washer tabs [8] up.
  6. Clean disk [4] with rubbing alcohol
  1. Place axle [3] in hub [5]
    CAUTION
    Be sure keys [1] are inserted cutouts [6] of hub [5].
  2. While holding speedometer drive gear assembly [4], tighten 19mm axle [3].
    See Torque Value Chart on last page.

INSTALL FRONT WHEEL: [P5]

  1. Lift wheel to installed position with left disk [2] between caliper brake pads [1].
  2. Check that axle ends [4] are between mounting studs [3].
    Flat side of nut [7] must face lock washer.
  3. Place left and right mounting caps [6] at installed position. Install lock washers and nuts [7].
  4. Check that gap [8] between mounting caps [6] and fork [9] is equal.
  5. Loosen or tighten nuts [7] until gap [8] is equal. See Torque Value Chart on last page.
  6. Insert speedometer cable [5] into drive gear assembly [10]. While spinning wheel, tighten speedometer cable.

INSTALL CALIPER BRAKE ASSEMBLY:

  1. Place lock washer and plain washer on two 14mm bolts [11].
  2. Place caliper brake assembly [12] at installed position. Install two 14mm bolts [11]. See Torque Value Chart on last page.
  3. Carefully install hydraulic brake pipe [9] in caliper brake assembly [12] fingertight
  4. Insert front brake hose [5] through rubber grommet [6]. Install grommet in hose bracket [4].
  5. Connect hose [5] to pipe [9].
  6. Place washers and brake hose [1,3] at installed position. Install washers and two 14mm oil bolts [2].
  7. While holding 17mm union-nut [7], tighten 10mm union-nut [8]. Tighten 10mm union-nut [10]. See Torque Value Chart on last page.
  8. Install rear view mirror, if removed.

AIR BLEEDING INSTRUCTIONS: [P6]

Master Cylinder

Following brands of brake fluid are recommended for use on your motorcycle: Atlas Extra Heavy DutyShell Super Heavy DutyTexaco Super Heavy DutyWagner Lockheed Heavy Duty

  1. Remove cap [2]. Remove rubber liner [8]. Fill reservoir [3] to full line [1]. Install rubber liner. Install cap.
  2. Slide rubber boor [6] down hose [7]. Remove 14mm oil bolt [5] and washers.
  3. Cover master cylinder outlet [4] with finger. Operate brake lever several times until brake fluid starts to flow from outlet.
  4. Place brake hose [7] and washer at install position, Install washer and 14mm oil bolt [5].
  5. Slide rubber boot [6] over outlet [4].

Caliper

  1. Pull left rubber cap [4] off. Connect clear plastic hose [3]. to left caliper bleeder valve [5].
  2. Insert other end of hose [3] into receptacle containing brake fluid. Be sure brake reservoir [6] is kept filled to full line [1] at all times during bleeding operation.
  3. Open bleeder valve [5]. Operate brake lever untill hose [3] is full of fluid. Close bleeder valve. Steps 4 and 5 should be repeated three times only before reservoir must be filled.
  4. Operate brake lever until lever becomes hard to squeeze.
  5. While depressing brake lever, open bleeder valve [5]. Allow fluid to flow until it stops. Close valve. Release brake lever.
  6. Repeat steps 4 and 5 until no air is visible in plastic hose [3].
  7. Remove cap [2]. Fill reservoir [6].
  8. Repeat this page of instruction to air bleed the right caliper brake.

ACTIVITY

  1. Spin wheel. Check that wheel spins freely. If wheel does not spin freely, have your brakes and wheels inspected by a Kawasaki dealer.
  2. Remove wooden box from under motorcycle and carefully lower motorcycle to ground.

TORQUE VALUE CHART

Description Tool Size Torque Value
Description Bolt Size Ft – lb Kg–m N–m
Master cylinder bolts 10mm 4.3 – 5.1 0.6 – 0.7 6 – 7
Brake bleeder valve 10mm 5.8 – 8.7 0.8 – 1.0 8 – 10
Pipe fittings 10mm 12.5 – 13 1.7 – 1.8 17 – 18
Four - Way fitting bolts 10mm 4.3 – 5.1 0.6 – 0.7 6 – 7
Front disc mounting bolts 12mm 10 – 13 1.4 – 1.8 14 – 18
Front fender mount bolts 13mm 14.5 – 15.5 2.0 – 2.2 20 – 22
Front axle clamping nuts 13mm 14.5 – 15.5 2.0 – 2.2 20 – 22
Oil bolts 14mm 18 – 24 2.5 – 3.3 25 – 33
Caliper brake assembly mounting bolts 14mm 18 – 24 2.5 – 3.3 25 – 33
Front axle 19mm 50 – 60 7.0 – 8.2 70 – 80

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