Kawasaki Ninja Service Manual: Master Cylinder Inspection (Visual Inspection)

Kawasaki Ninja Service Manual / Brakes / Master Cylinder / Master Cylinder Inspection (Visual Inspection)

If a master cylinder or piston shows any damage, replace them.

Master Cylinder Inspection (Visual Inspection)


If a cup is worn, damaged softened (rotted), or swollen, the piston assembly should be replaced to renew the cups.

If fluid leakage is noted at the brake lever, the piston assembly should be replaced to renew the cups.

If they are damaged, replace them.

If the springs are damaged, replace them.

If the relief port becomes plugged, the brake pads will drag on the disc. Blow the ports clean with compressed air.

Front Master Cylinder [I] Rear Master Cylinder [J]

Master Cylinder Inspection (Visual Inspection)


Rear Master Cylinder Installation
Replace the washers that are on each side of hose fitting with new ones. Install the brake hose [A]. Touch the brake hose to the stopper [B] of the rear master cylinder. Tighten: Torq ...

Brake Disc
...

Other materials:

DFI Parts Location
Main Throttle Sensor [A] Subthrottle Sensor [B] Idle Speed Control Valve Actuator [C] Subthrottle Valve Actuator [D] Intake Air Pressure Sensor #2 [E] Stick Coils #1, #2, #3, #4 [F] Air Switching Valve [G] Intake Air Pressure Sensor #1 [H] Water Temperature Sensor [A] Primary Fuel Injec ...

Lighting System
This motorcycle adopt the daylight system and have a headlight relay in the relay box. The headlight does not go on when the ignition switch and the engine stop switch are first turned on. The headlight comes on after the starter button is released and stays on until the ignition switch is turn ...

Front Caliper Removal
Remove: Bolt [A] Front Wheel Rotation Sensor [B] Loosen the banjo bolt [C] at the brake hose lower end, and tighten it loosely. Unscrew the caliper mounting bolts [D], and detach the caliper [E] from the disc. NOTICE Do not loosen the caliper assembly bolts [F]. Take out only ...