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:

Sprocket Wear Inspection
Visually inspect the engine and rear sprocket teeth for wear and damage. If the teeth are worn as illustrated, replace the sprocket, and inspect the drive chain wear (see Drive Chain Wear Inspection in the Periodic Maintenance chapter). Worn Tooth (Engine Sprocket) [A] Worn Tooth (Rear ...

Water Pump Housing Assembly
NOTICE Do not reuse the mechanical seal and oil seal. Apply high-temperature grease to the new oil seal lips [A]. Press the new oil seal into the housing with a bearing driver [B] until it stops at the bottom surface [C] of the housing. Special Tool - Bearing Driver Set: 57001-1129 ...

Rear Wheel Installation
Apply high-temperature grease to the grease seal lips. Fit the collars on the both sides of the hub. Left Side Collar [A] Right Side Collar [B] (with Flange) Engage the drive chain with the rear sprocket. Install the caliper bracket [A] onto the stopper [B] of the swingarm. ...