Kawasaki Ninja Service Manual: Caliper Installation

Kawasaki Ninja Service Manual / Brakes / Calipers / 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.

Caliper Installation

Touch the brake hoses [A] to the stopper [B] of the caliper.

Front Calipers [C] Rear Caliper [D]

Tighten: Torque - Front Caliper Mounting Bolts: 34 N·m (3.5 kgf·m, 25 ft·lb) Rear Caliper Pin Bolt: 27 N·m (2.8 kgf·m, 20 ft·lb) Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

Caliper Installation

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

WARNING

After servicing, it takes several applications of the brake lever or pedal before the brake pads contact the disc, which could result in increased stopping distance and cause an accident resulting in injury or death. Do not attempt to ride the motorcycle until a firm brake lever or pedal is obtained by pumping the lever or pedal until the pads are against the disc.

Front Caliper Disassembly

Refer to the Caliper Rubber Parts Replacement in the Periodic Maintenance chapter.

Front Caliper Assembly

Refer to the Caliper Rubber Parts Replacement in the Periodic Maintenance chapter.

Rear Caliper Disassembly

Refer to the Caliper Rubber Parts Replacement in the Periodic Maintenance chapter.

Rear Caliper Assembly

Refer to the Caliper Rubber Parts Replacement in the Periodic Maintenance chapter.

Rear Caliper Removal

Remove: Bolt [A] Rear Wheel Rotation Sensor [B] Loosen the banjo bolt [C] at the brake hose lower end, and tighten it loosely. Loosen the caliper holder pin [D]. Remove the rear wheel ( ...

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 ...

Other materials:

Brake Line Bleeding
The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed. When air enters the brake lines, brake lever or pedal movement will be partially used ...

Passenger’s Seat Removal
Remove the passenger’s seat by inserting the ignition key into the seat lock, and turning it clockwise. A. Seat Lock B. Ignition Key C. Passenger’s seat D. Pull up NOTE When removing the passenger’s seat, pull it up while turning the key. ...

Torque Limiter Removal
Remove: Starter Motor (see Starter Motor Removal in the Electrical System chapter) Throttle Body Assy Holder [A] Breather Hose [B] Roll up the heat insulation rubber plate [C]. Remove: Torque Limiter Cover Bolts [A] Torque Limiter Cover [B] Remove: Torque Limit ...