Kawasaki Ninja Service Manual: 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 [D].

Special Tool - Inside Circlip Pliers: 57001-143

• Unscrew the locknut [E] and pivot bolt [F], and remove the brake lever.
• Remove the bleed valve [G] and rubber cap [H].
• Remove the piston assembly [I] as follows.

Remove the dust cover and push rod.

Remove the circlip [J]

Pull out the piston (with primary cup and secondary cup).

Remove the return spring and spring guide.

• Replace: Seal Cover [A] Circlip [B] O-ring [D] Rubber Cap [H] Piston Assembly [I] Circlip [J] Diaphragm [K]

Rear Master Cylinder Disassembly

• Remove the rear master cylinder (see Rear Master Cylinder Removal in the Brakes chapter).
• Remove the circlip [A], connector [B] and O-ring [C].

Special Tool - Inside Circlip Pliers: 57001-143

• Slide the dust cover [D] out of place, and remove the circlip [E].
• Pull out the push rod assembly [F].
• Remove the piston assembly [G] and return spring.

Master Cylinder Assembly

• Before assembly, clean all parts including the master cylinder with brake fluid or alcohol.

NOTICE

Except for the disc pads and disc, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol for cleaning brake parts. Do not use any other fluid for cleaning these parts. Gasoline, engine oil, or any other petroleum distillate will cause deterioration of the rubber parts. Oil spilled on any part will be difficult to wash off completely, and will eventually deteriorate the rubber used in the disc brake.

• Apply brake fluid to each parts and the inner wall of the cylinder.
• When installing the piston assembly, take care not to scratch the piston or the inner wall of the cylinder.
• Apply silicone grease to the followings.

Front: Brake Lever Pivot Bolt

Rear: Dust Cover of Push Rod Assembly

• For the front master cylinder, tighten the brake lever pivot bolt and the locknut.

Torque - Brake Lever Pivot Bolt: 1.2 N·m (0.12 kgf·m, 11 in·lb) Brake Lever Pivot Bolt Locknut: 5.9 N·m (0.60 kgf·m, 52 in·lb)

• For the front master cylinder, install the bleed valve and rubber cap.

Torque - Front Master Cylinder Bleed Valve: 5.4 N·m (0.55 kgf·m, 48 in·lb)

• Fit the circlip into the groove of the cylinder securely.