Kawasaki Ninja Service Manual: 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)

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

• 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)

• 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.

• 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)

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