Kawasaki Ninja Service Manual: Front Master Cylinder Installation

Kawasaki Ninja Service Manual / Brakes / Master Cylinder / Front Master Cylinder Installation

Apply silicone grease to the sliding surface of the brake lever pivot bolt.
Tighten: Torque - Brake Lever Pivot Bolt: 1.2 N·m (0.12 kgf·m, 11 in·lb) Brake Lever Pivot Bolt Nut: 5.9 N·m (0.60 kgf·m, 52 in·lb)
Assemble the reservoir [A] and the bracket [B] as shown in the figure.

Damper [C] Collar [D] Bolt [E] Nut [F]
Install the front brake light switch.
Tighten: Torque - Front Brake Light Switch Screw: 1.2 N·m (0.12 kgf·m, 11 in·lb)

Front Master Cylinder Installation

Install the master cylinder clamp [A] so that the arrow mark [B] faces upward.

Front Master Cylinder Installation

Set the front master cylinder to match its mating surface [A] to the punch mark [B] of the handlebar.
Tighten the upper clamp bolt first, and then the lower clamp bolt.

Torque - Front Master Cylinder Clamp Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)

Front Master Cylinder Installation

Connect the front brake light switch connector [A] as shown in the figure.
Replace the washers that are on each side of the hose fitting with new ones.

Front Master Cylinder Installation

Install the brake hose [A].

Touch the brake hose to the stopper [B] of the front master cylinder.

Tighten: Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

Front Master Cylinder Installation

Bleed the brake line (see Brake Line Bleeding).
Check the brake for good braking power, no brake drag, and no fluid leakage.

Front Master Cylinder Removal

Remove the reservoir mounting bolt and nut [A]. Unscrew the banjo bolt [A] and disconnect the brake hose from the master cylinder (see Brake Hose and Pipe Replacement in the Periodic ...

Rear Master Cylinder Removal

Unscrew the brake hose banjo bolt [A] and remove the brake hose (see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter). Remove: Rear Master Cylinder Mounting Bolts [B] ...

Other materials:

Fuses
Fuses are arranged in the fuse boxes located under the passenger’s seat and in the left fairing. The main fuse is located under the passenger’s seat. If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of proper amp ...

Air Cleaner Oil Draining
A drain hose is connected to the bottom of the air cleaner to drain water or oil accumulated in the cleaner part. Visually check the drain hose [A] if the water or oil accumulates. If any water or oil accumulates in the hose, remove the plug [B] from the drain hose and drain it. ...

Rear Wheel Rotation Sensor Wiring Inspection (Service Code b 45)
Disconnect the rear wheel rotation sensor lead connector [A] (see Rear Wheel Rotation Sensor Removal in the Brakes chapter). Disconnect the KIBS hydraulic unit lead connector (see KIBS Hydraulic Unit Removal in the Brakes chapter). Check the wiring continuity of the G lead and R ...