Kawasaki Ninja Service Manual: 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.

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.

• 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).

• 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)