Kawasaki Ninja Service Manual: Rear Master Cylinder Installation

Kawasaki Ninja Service Manual / Brakes / Master Cylinder / Rear Master Cylinder Installation

Replace the washers that are on each side of hose fitting with new ones.
Install the brake hose [A].

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

Tighten: Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)
Install the master cylinder, the bracket and other parts (see Brake Pedal Installation).
Bleed the brake line (see Brake Line Bleeding).
Check the brake for good braking power, no brake drag, and no fluid leakage.

Rear Master Cylinder Installation

Front Master Cylinder Disassembly

Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter.

Rear Master Cylinder Disassembly

Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter.

Master Cylinder Assembly

Refer to the Master Cylinder Rubber Parts Replacement in the Periodic Maintenance chapter.

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] ...

Master Cylinder Inspection (Visual Inspection)

Remove the master cylinders (see Front/Rear Master Cylinder Removal). Disassemble the front and rear master cylinders (see Master Cylinder Rubber Parts Replacement in the Periodic Maintenan ...

Other materials:

Rear Wheel Rotation Sensor Signal (Service Code 24)
Rear Wheel Rotation Sensor Signal Inspection The rear wheel rotation sensor sends the signal to the ECU through the KIBS hydraulic unit (KIBS equipped models). For other than KIBS equipped models, the signal is sent directly to the ECU. The ECU uses the rear wheel rotation sensor signal for mo ...

Self-Diagnosis Outline
The self-diagnosis system is monitoring the following mechanisms. DFI System and Ignition System S-KTRC System Immobilizer System (Equipped Models) KIBS and ABS (Equipped Models) ESD (Electronic Steering Damper) System (ZX1000JD/KD) The following warning indicator lights (LED) are used for ...

Piston Installation
Apply molybdenum disulfide oil solution to the oil ring expander, and install the oil ring expander [A] in the bottom piston ring groove so the ends [B] not butt together Applymolybdenum disulfide oil solution to the oil ring steel rails, and install the oil ring steel rails, one above th ...