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:

Special Tools
Inside Circlip Pliers: 57001-143 Oil Seal & Bearing Remover: 57001-1058 Bearing Driver Set: 57001-1129 Jack: 57001-1238 Bearing Remover Head, 15 × 17: 57001-1267 Fork Oil Level Gauge: 57001-1290 Bearing Remover Shaft, 13: 57001-1377 Fork Oil Seal Driver, 43: 57001-15 ...

Throttle Body Assy Installation
Apply a thin coat of grease to the throttle cable lower ends. Fit the accelerator cable end [A] and the decelerator cable end [B] into the throttle pulley. Install the clamp [C] securely. Install the throttle body assy holder clamp bolt heads [A] outside as shown in the figure. ...

Intake Air Pressure Sensor #1 Installation
NOTE The intake air pressure sensor #1 is the same part as the intake air pressure sensor #2. Installation is basically the reverse of removal. Position the intake air pressure sensor #1 [A] between the projections [B] on the rubber damper. Install the rubber damper [A] on the bracket ...