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:

Special Tools
Inside Circlip Pliers: 57001-143 Oil Seal & Bearing Remover: 57001-1058 Bearing Driver Set: 57001-1129 Jack: 57001-1238 Bearing Remover Head, 15 × 17: 57001-1267 Fork Oil Level Gauge: 57001-1290 Bearing Remover Shaft, 13: 57001-1377 Fork Oil Seal Driver, 43: 57001-15 ...

Moving Off
Check that the side stand is up. Pull in the clutch lever. Shift into 1st gear. Open the throttle a little, and start to let out the clutch lever very slowly. As the clutch starts to engage, open the throttle a littlemore, giving the engine just enough fuel to keep it from stallin ...

KIBS Equipped Models
1. Clutch Cable 2. Vacuum Hose (Equipped Models) 3. Left Switch Housing Lead 4. Main Harness 5. Front Brake Hose 6. Throttle Cables 7. Right Switch Housing Lead 8. Bracket (Hold the brake pipes.) 9. Run the meter lead to outside of the meter bracket. 10. Run the vacuum hoses to inside o ...