Kawasaki Ninja Service Manual: Front Master Cylinder Installation

Kawasaki Ninja Service Manual / Brakes / Master Cylinder / 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·m (0.60 kgf·m, 52 in·lb)
Assemble the reservoir [A] and the bracket [B] as shown in the figure.

Damper [C] Collar [D] Bolt [E] Nut [F]
Install the front brake light switch.
Tighten: Torque - Front Brake Light Switch Screw: 1.2 N·m (0.12 kgf·m, 11 in·lb)

Front Master Cylinder Installation

Install the master cylinder clamp [A] so that the arrow mark [B] faces upward.

Front Master Cylinder Installation

Set the front master cylinder to match its mating surface [A] to the punch mark [B] of the handlebar.
Tighten the upper clamp bolt first, and then the lower clamp bolt.

Torque - Front Master Cylinder Clamp Bolts: 11 N·m (1.1 kgf·m, 97 in·lb)

Front Master Cylinder Installation

Connect the front brake light switch connector [A] as shown in the figure.
Replace the washers that are on each side of the hose fitting with new ones.

Front Master Cylinder Installation

Install the brake hose [A].

Touch the brake hose to the stopper [B] of the front master cylinder.

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

Front Master Cylinder Installation

Bleed the brake line (see Brake Line Bleeding).
Check the brake for good braking power, no brake drag, and no fluid leakage.

Front Master Cylinder Removal

Remove the reservoir mounting bolt and nut [A]. Unscrew the banjo bolt [A] and disconnect the brake hose from the master cylinder (see Brake Hose and Pipe Replacement in the Periodic ...

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] ...

Other materials:

Solenoid Valve Inspection (Service Code b 13, b 14, b 17, b 18)
The solenoid valve is built in the KIBS Hydraulic Unit [A]. Therefore the solenoid valve cannot be checked directly. Perform the Pre-Diagnosis Inspection 1 and 2 (see Inquiries to Rider in the Brakes chapter). If any of these service codes appears even if all checks are ended, replace t ...

IC Igniter Inspection
The IC igniter is built in the ECU [A]. Refer to the following items. Interlock Operation Inspection (see Interlock Operation Inspection) Ignition System Troubleshooting (see Ignition System section) ECU Power Supply Inspection (see ECU Power Supply Inspection in the Fuel System (D ...

Technical Information - Electronic Steering Damper (ESD/ZX1000JD/KD models)
1) Overview This model has an Electronic Steering Damper (ESD) [A]. Unlike conventional manual adjustment method of Kawasaki, damping characteristics are adjusted by the electronic control unit. 2) Purpose Designed to offer increased stability at high speed without interfering with light ...