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:

Rear Fender Front Installation
Installation is the reverse of removal. Note the following. Run the harness, cables and leads correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). When installing the clamp [A] on the rear fender front [B], install it so that the clamp positions at near the ...

Tie-Rod and Rocker Arm Bearing Installation
Replace the needle bearings [A] and oil seals with new ones. Apply plenty of grease to the lips of the oil seals. Install the needle bearings and oil seals position as shown in the figure. Screw the needle bearing driver into the driver holder. Insert the needle bearing driver into th ...

Radiator Cap Inspection
Remove: Radiator Cap (see Coolant Change in the Periodic Maintenance chapter) Check the condition of the bottom [A] and top [B] valve seals and valve spring [C]. If any one of them shows visible damage, replace the cap with a new one. Install the cap [A] on a cooling system pr ...