Kawasaki Ninja Service Manual: Brake Hose and Pipe Replacement

Kawasaki Ninja Service Manual / Periodic Maintenance / Periodic Maintenance Procedures / Replacement Parts / Brake Hose and Pipe Replacement

NOTICE

Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately.

Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Brake Hose Fitting Bolt [A] Brake Hose Banjo Bolts [B] Bolt [C] Clamps [D]
When removing the brake hoses [E], note the following.

Brake Hose and Pipe Replacement

Take care not to spill the brake fluid on the painted or plastic parts.

Temporarily secure the end of the brake hose to some high place to keep fluid loss to a minimum.

Immediately wash away any brake fluid that spills.

When installing the brake hoses, note the following.

Brake Hose and Pipe Replacement

Avoid sharp bending, kinking, flatting or twisting, and run the hoses according to Cable, Wire, and Hose Routing section in the Appendix chapter.
There are washers on each side of the brake hose fitting.

Replace them with new ones.
Tighten:

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

Fill the brake line after installing the brake hose (see Brake Fluid Change).

Brake Hose and Pipe Replacement

For KIBS equipped models; note the following.

NOTE

When removing the brake pipes and hoses on the hydraulic unit, remove them according to each assembly of the exploded view in the Brakes chapter.

Remove: Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Rear Fender Front (see Rear Fender Front Removal in the Frame chapter) Rear Shock Absorber (see Rear Shock Absorber Removal in the Suspension chapter) Swingarm (see Swingarm Removal in the Suspension chapter) Rocker Arm (see Rocker Arm Removal in the Suspension chapter) Steering Damper Mounting Bracket [A] Brake Pipe Joint Nuts [B] Brake Hose Banjo Bolts [C] Bolts [D] Clamps [E] Grommet [F] Band [G]
Before installing the brake pipe, check to see that there is no damage on the threads of the brake pipe joint nut.

If there is any damage, replace the damaged parts with new ones.

NOTE

Tighten the brake pipe joint nuts at both ends of the brake pipe temporarily and then tighten them to the specified torque.

Install the brake pipes and brake hoses to the specified angle (see Cable, Wire, and Hose Routing section in the Appendix chapter).
Tighten the brake pipe joint nuts with the flare nut wrench.
Tighten:

Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb) Brake Pipe Joint Nuts: 18 N·m (1.8 kgf·m, 13 ft·lb)

Brake Hose and Pipe Replacement

Oil Filter Replacement

Drain the engine oil (see Engine Oil Change). Remove the left lower fairing (see Lower Fairing Removal in the Frame chapter). Remove the oil filter [A] with the oil filter wrench [B]. Spec ...

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] ...

Other materials:

Rear Shock Absorber Removal
Remove: Lower Fairings (see Lower Fairing Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System chapter) Bolts [A] (Both Sides) Foot Guard [B] (Both Sides) Squeeze the brake lever slowly and hold it with a band [A]. WARNINGBe sure to h ...

Torque and Locking Agent
The following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “Remarks” column mean: AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque. G: Apply ...

Spring Tension Inspection
Since a spring becomes shorter as it weakens, check its free length [A] to determine its condition. If the spring of either fork leg is shorter than the service limit, it must be replaced. If the length of a replacement spring and that of the remaining spring vary greatly, the remaining s ...