Kawasaki Ninja Service Manual: Caliper Fluid Seal Damage

Kawasaki Ninja Service Manual / Brakes / Calipers / Caliper Fluid Seal Damage

The fluid seal (piston seal) [A] is placed around the piston to maintain clearance between the pad and the disc. If the seal is in a poor condition, it could lead the pad to wear excessively or the brake to drag, which may cause the temperature of the discs or the brake fluid to increase.

Caliper Fluid Seal Damage


Brake fluid leakage around the pad.

Brakes overheat.

Considerable difference in inner and outer pad wear.

Seal and piston are stuck together.

If the fluid seal is replaced, replace the dust seal [B] as well. Also, replace all seals every other time the pads are changed.

Front Caliper [C] Rear Caliper [D]

Caliper Fluid Seal Damage


Caliper Installation
Install the caliper and brake hose lower end. For the front caliper, be sure to install the collars [A]. Replace the washers on each side of hose fitting with new ones. Touch the brake ho ...

Rear Caliper Dust Boot and Friction Boot Damage
Check that the dust boot [A] and friction boot [B] are not cracked, worn, swollen, or otherwise damaged. If they show any damage, replace it. ...

Other materials:

Intake Air Temperature Sensor Removal
NOTICE Never drop the intake air temperature sensor especially on a hard surface. Such a shock to the sensor can damage it. Remove the fuel tank (see Fuel Tank Removal in the Fuel System (DFI) chapter). Disconnect the connector [A] from the intake air temperature sensor. Remove the da ...

Exploded View
25. “1T� marked side faces up. 26. “T2� marked side faces up. 27. Hollow mark faces exhaust side. G: Apply grease. L: Apply a non-permanent locking agent. LG: Apply liquid gasket. M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil solution. ...

Transmission Shaft Assembly
Apply molybdenum disulfide oil solution to the sliding surfaces of the gears and shafts. Install the gears and the gear bushings [A] with their holes [B] aligned. Replace any circlips removed with new ones. Install the circlips [A] so that the opening [B] of it is aligned with ...