Kawasaki Ninja Service Manual: Master Cylinder Rubber Parts Replacement

Kawasaki Ninja Service Manual / Periodic Maintenance / Periodic Maintenance Procedures / Replacement Parts / 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.

Master Cylinder Rubber Parts Replacement

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

Rear Master Cylinder Disassembly

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.

Brake Fluid Change

NOTE The procedure to change the front brake fluid is as follows. Changing the rear brake fluid is the same as for the front brake. Level the brake fluid reservoir. Remove: Screw [A] ...

Caliper Rubber Parts Replacement

Front Caliper Disassembly Remove: Front Caliper (see Front Caliper Removal in the Brakes chapter) Brake Pads (see Front Brake Pad Removal in the Brakes chapter) Remove: Front Caliper A ...

Other materials:

Special Tools and Sealant
Compression Gauge, 20 kgf/cm²: 57001-221 Valve Spring Compressor Assembly: 57001-241 Valve Spring Compressor Adapter, 25: 57001-1019 Valve Seat Cutter, 45° - 27.5: 57001-1114 Valve Seat Cutter, 45° - 32: 57001-1115 Valve Seat Cutter, 32° - 28: 57001-1119 Valve Seat Cutter ...

Shift Drum Assembly
Press and insert the ball bearing [A] on the shift drum [B] until it is bottomed. Install: Ball Bearing [C] Dowel Pin [D] and Shift Drum Cam [E] Align the pin with the groove in the shift drum cam. Apply a non-permanent locking agent to the shift drum cam holder bolt [F]. Tight ...

Front Brake Pad Installation
Check that the pad spring [A] is in place on the caliper. Push the caliper pistons in by hand as far as they will go. Install the brake pads [A] on the pad spring correctly. Fit the pad into the groove of the caliper as shown in the figure. Install the pad pins while pushing t ...