Kawasaki Ninja Service Manual: Caliper Rubber Parts Replacement

Kawasaki Ninja Service Manual / Periodic Maintenance / Periodic Maintenance Procedures / Replacement Parts / Caliper Rubber Parts Replacement

Front Caliper Disassembly

Front Caliper Disassembly


Front Caliper Disassembly


Front Caliper Disassembly


Install a rubber gasket [A] and a wooden board [B] more than 10 mm (0.4 in.) thick on the caliper half.

For inside caliper half [C], fasten them together with a suitable bolt and nut [D] as shown. Leave one of the oil passage [E] open.

Lightly apply compressed air [F] to the oil passage until the pistons hit the rubber gasket.

Push down [G]

Front Caliper Disassembly


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.

Front Caliper Disassembly


NOTE

Front Caliper Assembly

NOTICE

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

Torque - Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb)

Apply silicone grease to the fluid seals, and install them into the cylinders by hand.

Apply silicone grease to the dust seals, and install them into the cylinders by hand.

Front Caliper Assembly


Torque - Front Caliper Assembly Bolts: 22 N·m (2.2 kgf·m, 16 ft·lb)

Front Caliper Assembly


Front Caliper Assembly


Rear Caliper Disassembly

Rear Caliper Disassembly


Rear Caliper Disassembly


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.

Rear Caliper Disassembly


WARNING

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

NOTE

Rear Caliper Assembly

NOTICE

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

Torque - Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb)

Apply silicone grease to the fluid seal, and install it into the cylinder by hand.

Apply silicone grease to the dust seal, and install it into the cylinder by hand.

Rear Caliper Assembly


Rear Caliper Assembly


Torque - Rear Caliper Pin Bolt: 27 N·m (2.8 kgf·m, 20 ft·lb)

Rear Caliper Assembly


Master Cylinder Rubber Parts Replacement
Front Master Cylinder Disassembly Remove the front master cylinder (see Front Master Cylinder Removal in the Brakes chapter). Remove the seal cover [A], circlip [B], connector [C] and O-ring ...

Spark Plug Replacement
Remove the stick coils (see Stick Coil Removal in the Electrical System chapter). Remove the spark plugs using the 16 mm (0.63 in.) plug wrench [A] vertically. Replace the spark plug with n ...

Other materials:

Coolant Filling
Remove the bolts and quick rivets. Detach the tabs and remove the right fairing and cover. A. Bolts B. Quick Rivet C. Large Quick Rivet D. Tabs E. Right Fairing and Cover NOTE The right fairing and cover uses the quick rivets and large quick rivet. The large quick rivet ca ...

Spark Plugs
The standard spark plug is shown in the table. The spark plugs should be replaced in accordance with the Periodic Maintenance Chart. Spark plug removal should be done only by a competent mechanic following the instructions in the Service Manual. Spark Plug A. Plug Gap ...

Tie-Rod and Rocker Arm Bearing Installation
Replace the needle bearings [A] and oil seals with new ones. Apply plenty of grease to the lips of the oil seals. Install the needle bearings and oil seals position as shown in the figure. Screw the needle bearing driver into the driver holder. Insert the needle bearing driver into th ...