Kawasaki Ninja Service Manual: 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 Assembly Bolts [A]
• Split the front caliper.

• Remove: Pad Spring O-ring [A]

• Using compressed air, remove the pistons. One way to remove the pistons is as follows.

Install a rubber gasket [A] and a wooden board [B] more than 10 mm (0.4 in.) thick on the caliper half.

For inside caliper half [C], fasten them together with a suitable bolt and nut [D] as shown. Leave one of the oil passage [E] open.

Lightly apply compressed air [F] to the oil passage until the pistons hit the rubber gasket.

Push down [G]

Pull out the pistons by hand.

• Remove the dust seals [A] and fluid seals [B].
• Remove the bleed valve [C] and rubber cap [D].
• Repeat the previous step to remove the pistons from the other side of the caliper body.

NOTE

• If compressed air is not available, do as follows for both calipers coincidentally, with the brake hose connected to the caliper.
• Prepare a container for brake fluid, and perform the work above it.
• Remove the pad springs and pads (see Front Brake Pad Removal in the Brakes chapter).
• Pump the brake lever until the pistons come out of the cylinders, and then disassemble the caliper.

Front Caliper Assembly

• Clean the caliper parts except for the pads.

NOTICE

For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol.

• Install the bleed valve and rubber cap.

Torque - Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb)

• Replace the fluid seals [A] with new ones.

Apply silicone grease to the fluid seals, and install them into the cylinders by hand.

• Replace the dust seals [B] with new ones.

Apply silicone grease to the dust seals, and install them into the cylinders by hand.

• Replace the O-ring [A] and install it.
• Apply brake fluid to the outside of the pistons, and push them into each cylinder by hand.
• Be sure to install the O-ring.
• Tighten:

Torque - Front Caliper Assembly Bolts: 22 N·m (2.2 kgf·m, 16 ft·lb)

• Install the pad spring [A] as shown.
• Install the brake pads (see Front Brake Pad Installation in the Brakes chapter).
• Wipe up any spilled brake fluid on the caliper with wet cloth.

Rear Caliper Disassembly

• Remove: Rear Caliper (see Rear Caliper Removal in the Brakes chapter) Brake Pads (see Rear Brake Pad Removal in the Brakes chapter) Bolt [A] Caliper Bracket [B]

• Remove: Pad Spring [A] Dust Boot [B]

• Using compressed air, remove the piston.

Cover the caliper opening with a clean, heavy cloth [A].

Remove the piston by lightly applying compressed air [B] to where the brake line fits into the caliper.

• Remove the dust seal and fluid seal.
• Remove the bleed valve and rubber cap.

NOTE

• If compressed air is not available, do as follows with the brake hose connected to the caliper.
• Prepare a container for brake fluid, and perform the work above it.
• Remove the pads (see Rear Brake Pad Removal in the Brakes chapter).
• Pump the brake pedal to remove the caliper piston.

Rear Caliper Assembly

• Clean the caliper parts except for the pads.

NOTICE

For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol.

• Install the bleed valve and rubber cap.

Torque - Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb)

• Replace the fluid seal [A] with a new one.

Apply silicone grease to the fluid seal, and install it into the cylinder by hand.

• Replace the dust seal [B] with a new one.

Apply silicone grease to the dust seal, and install it into the cylinder by hand.

• Install the pad spring [A] in the caliper as shown in the figure.
• Apply brake fluid to the outside of the piston [B], and push it into the cylinder by hand.
• Replace the and dust boot [C].

• Install the pad spring [A] on the caliper bracket as shown in the figure.
• Apply a silicone grease to the caliper bracket shaft [B].
• Replace the friction boot [C].
• Assemble the caliper and the caliper bracket.
• Apply silicone grease to the rear caliper pin bolt.
• Tighten:

Torque - Rear Caliper Pin Bolt: 27 N·m (2.8 kgf·m, 20 ft·lb)

• Install the pads (see Rear Brake Pad Installation in the Brakes chapter).
• Wipe up any spilled brake fluid on the caliper with wet cloth.