Kawasaki Ninja Service Manual: Caliper Rubber Parts Replacement

Kawasaki Ninja Service Manual / Periodic Maintenance / Periodic Maintenance Procedures / Replacement Parts / Caliper Rubber Parts Replacement

Front Caliper Disassembly

Front Caliper Disassembly


Front Caliper Disassembly


Front Caliper Disassembly


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]

Front Caliper Disassembly


WARNING

The piston in the brake caliper can crush hands and fingers. Never place your hand or fingers in front of the piston.

Pull out the pistons by hand.

Front Caliper Disassembly


NOTE

Front Caliper Assembly

NOTICE

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

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

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

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

Front Caliper Assembly


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

Front Caliper Assembly


Front Caliper Assembly


Rear Caliper Disassembly

Rear Caliper Disassembly


Rear Caliper Disassembly


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.

Rear Caliper Disassembly


WARNING

The piston in the brake caliper can crush hands and fingers. Never place your hand or fingers in front of the piston.

NOTE

Rear Caliper Assembly

NOTICE

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

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

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

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

Rear Caliper Assembly


Rear Caliper Assembly


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

Rear Caliper Assembly


Master Cylinder Rubber Parts Replacement
Front Master Cylinder Disassembly Remove the front master cylinder (see Front Master Cylinder Removal in the Brakes chapter). Remove the seal cover [A], circlip [B], connector [C] and O-ring ...

Spark Plug Replacement
Remove the stick coils (see Stick Coil Removal in the Electrical System chapter). Remove the spark plugs using the 16 mm (0.63 in.) plug wrench [A] vertically. Replace the spark plug with n ...

Other materials:

Model Identification
ZX1000JB (US and CA Models) Left Side View ZX1000JB (US and CA Models) Right Side View ZX1000JB (EUR Models) Left Side View ZX1000JB (EUR Models) Right Side View ZX1000KB (US and CA Models) Left Side View ZX1000KB (US and CA Models) Right Side View ZX1000KB (EUR Models) ...

Wheel Inspection
Raise the front/rear wheel off the ground. Special Tools - Jack: 57001-1238 Jack Attachment: 57001-1608 Spin the wheel lightly, and check for roughness or binding. If roughness or binding is found, replace the hub bearings (see Hub Bearing Removal/Installation). Inspect the wh ...

Unit Setting
The unit setting in the meter instrument can be changed according to local regulations. Make sure the unit setting is correctly displayed before riding. A. Speedometer B. Meter Display Units NOTE Do not operate the motorcycle with wrong unit (mph or km/h) of the speedometer. To change ...