Kawasaki Ninja Service Manual: Rear Master Cylinder Removal

Kawasaki Ninja Service Manual / Brakes / Master Cylinder / 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] Foot Guard [C] Screw and Stopper [D] Bolt [E] Front Footpeg Bracket Bolts [F] Cable Guide [G]

Rear Master Cylinder Removal

Remove: Cotter Pin [A] Joint Pin [B]

Rear Master Cylinder Removal

Slide the clamp [A].
Pull off the reservoir hose lower end [B], and drain the brake fluid into a container.

Rear Master Cylinder Removal

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· ...

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 ...

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Hub Bearing Installation
Before installing the hub bearings, blow any dirt or foreign particles out of the hub with compressed air to prevent contamination of the bearings. Replace the bearings with new ones. Install the bearings by using the bearing driver set which does not contact the bearing inner race. ...

Spring Plate Free Play Measurement
Insufficient clutch free play will cause the engine braking effect to be more sudden, resulting in rear wheel hop. On the other hand, if the free play is excessive, the clutch lever may feel “spongy” or pulsate when pulled. Hold an extra drive shaft in a vise and install the following c ...

Throttle Grip and Cables
Free Play Inspection Refer to the Throttle Control System Inspection in the Periodic Maintenance chapter. Free Play Adjustment Refer to the Throttle Control System Inspection in the Periodic Maintenance chapter. Cable Installation Install the throttle cables in accordance with the Cable, ...