Kawasaki Ninja Service Manual: Master Cylinder Rubber Parts Replacement

Kawasaki Ninja Service Manual / Periodic Maintenance / Periodic Maintenance Procedures / Replacement Parts / Master Cylinder Rubber Parts Replacement

Front Master Cylinder Disassembly

Special Tool - Inside Circlip Pliers: 57001-143

Remove the dust cover and push rod.

Remove the circlip [J]

Pull out the piston (with primary cup and secondary cup).

Remove the return spring and spring guide.

Master Cylinder Rubber Parts Replacement


Rear Master Cylinder Disassembly

Special Tool - Inside Circlip Pliers: 57001-143

Rear Master Cylinder Disassembly


Master Cylinder Assembly

NOTICE

Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, engine oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the disc brake.

Front: Brake Lever Pivot Bolt

Rear: Dust Cover of Push Rod Assembly

Torque - Brake Lever Pivot Bolt: 1.2 N·m (0.12 kgf·m, 11 in·lb) Brake Lever Pivot Bolt Locknut: 5.9 N·m (0.60 kgf·m, 52 in·lb)

Torque - Front Master Cylinder Bleed Valve: 5.4 N·m (0.55 kgf·m, 48 in·lb)

Brake Fluid Change
NOTE The procedure to change the front brake fluid is as follows. Changing the rear brake fluid is the same as for the front brake. Level the brake fluid reservoir. Remove: Screw [A] ...

Caliper Rubber Parts Replacement
Front Caliper Disassembly Remove: Front Caliper (see Front Caliper Removal in the Brakes chapter) Brake Pads (see Front Brake Pad Removal in the Brakes chapter) Remove: Front Caliper A ...

Other materials:

KIBS Hydraulic Unit Communication Error (Service Code 1b, KIBS Equipped Models)
KIBS Hydraulic Unit Communication Line Inspection When the data (for status of KIBS hydraulic unit) is not sent from the KIBS hydraulic unit to the meter unit and ECU, the service code 1b is displayed. The data is sent through the CAN communication line. The service code 1b is detected with the ...

Separator Operation Test
WARNINGGasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. ...

Subthrottle Valve Actuator Input Voltage Inspection
NOTE Be sure the battery is fully charged. Turn the ignition switch to OFF. Disconnect the subthrottle valve actuator connector and connect the measuring adapter [A] between these connectors as shown in the figure. Main Harness [B] Subthrottle Valve Actuator [C] Special Tool ...