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:

Drive Chain Wear Inspection
Remove the chain cover (see Drive Chain Removal/Installation in the Final Drive chapter). Rotate the rear wheel to inspect the drive chain for damaged rollers, and loose pins and links If there is any irregularity, replace the drive chain. Lubricate the drive chain if it appears dry. ...

Cylinder (Upper Crankcase) Wear Inspection
Split the crankcase (see Crankcase Splitting). Remove the pistons (see Piston Removal). Assemble the cylinder (upper crankcase) [A], the cylinder head [B] and the cylinder head gasket [C]. Tighten the cylinder head bolts (see Cylinder Head Installation in the Engine Top End chapter). ...

Troubleshooting Guide
NOTE Refer to the Fuel System chapter for most of DFI trouble shooting guide. This is not an exhaustive list, giving every possible cause for each problem listed. It is meant simply as a rough guide to assist the troubleshooting for some of the more common difficulties. Engine Doe ...