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:

Chain Slack Adjustment
Remove the cotter pin, and loosen the axle nut. Loosen the left and right chain adjuster locknuts. A. Axle Nut B. Cotter Pin C. Adjuster D. Locknut If the chain is too loose, turn out the left and right chain adjusters evenly. If the chain is too tight, turn in the left ...

Maintenance and adjustment
The maintenance and adjustments outlined in this chapter must be carried out in accordance with the Periodic Maintenance Chart to keep the motorcycle in good running condition. The initial maintenance is vitally important and must not be neglected. With a basic knowledge of mechanics and the ...

For Secondary Fuel Injectors
Remove the fuel tank (see Fuel Tank Removal). Disconnect the injector connector and connect the harness adapter [A] between these connectors as shown in the figure. Main Harness [B] Secondary Fuel Injector #1 [C] Special Tool - Measuring Adapter: 57001-1700 Connect a digital me ...