Front Caliper Removal
- Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely.
- Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc.
- Unscrew the banjo bolt and remove the brake hose(s) [D] from the caliper (See Brake Hose and Pipe Replacement in the Periodic Maintenance chapter).
Caution: Immediately wash away any brake fluid that spills.
![](https://motoinstruction.ru/img/kawasaki/23/128814.jpg)
Note: If the caliper is to be disassembled after removal and if compressed air is not available, disassemble the caliper before the brake hose is removed (See Caliper Rubber Parts Replacement in the Periodic Maintenance chapter).
Rear Caliper Removal
- Loosen the banjo bolt [A] at the brake hose lower end, and tighten it loosely.
- Unscrew the caliper mounting bolts [B], and detach the caliper [C] from the disc.
- Unscrew the banjo bolt and remove the brake hose [D] from the caliper (See Brake Hose and Pipe Replacement in the Periodic Maintenance chapter).
Caution: Immediately wash away any brake fluid that spills.
![](https://motoinstruction.ru/img/kawasaki/23/128815.jpg)
Note: If the caliper is to be disassembled after removal and if compressed air is not available, disassemble the caliper before the brake hose is removed (See Caliper Rubber Parts Replacement in the Periodic Maintenance chapter).
Caliper Installation
- Install the caliper and brake hose lower end.
Replace the washers on each side of hose fitting with new ones.
Tighten:
Torque - Caliper Mounting Bolts
Front: 34 Nm (3.5 kgf·m, 25 ft·lb)
Rear: 25 Nm (2.5 kgf·m, 18 ft·lb)
Brake Hose Banjo Bolts: 25 Nm (2.5 kgf·m, 18 ft·lb)
- Bleed the brake line (See Brake Line Bleeding).
- Check the brake for good braking power, no brake drag, and no fluid leakage.
Warning: Do not attempt to drive the motorcycle until a full brake lever or pedal is obtained by pumping the brake lever or pedal until the pads are against the disc. The brakes will not function on the first application of the lever or pedal if this is not done.
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.
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 brake to drag, which may cause the temperature of the discs or the brake fluid to increase.
- Replace the fluid seal if it exhibits any of the conditions listed below.
Brake fluid leakage around the pad.
Brakes overheat.
Considerable difference in inner and outer pad wear. OSeal and piston are stuck together.
![](https://motoinstruction.ru/img/kawasaki/23/128816.jpg)
If the fluid seal is replaced, replace the dust seal [B] as well. Also, replace all seals every other time the pads are changed.
![](https://motoinstruction.ru/img/kawasaki/23/128817.jpg)
Rear Caliper Dust Boot and Friction Boot Damage
- Check that the dust boot [A] and friction boot [B] are not cracked, worn, swollen, or otherwise damaged.
If they show any damage, replace it.
![](https://motoinstruction.ru/img/kawasaki/23/128818.jpg)
Caliper Piston and Cylinder Damage
- Visually inspect the pistons [A] and cylinder surfaces [B].
Replace the caliper if the cylinder and piston are badly scores or rusty.
![](https://motoinstruction.ru/img/kawasaki/23/128819.jpg)
![](https://motoinstruction.ru/img/kawasaki/23/128820.jpg)
Rear Caliper Holder Shaft Wear
The caliper body must slide smoothly on the caliper holder shafts [A]. If the body does not slide smoothly, one pad will wear more than the other, pad wear will increase, and constant drag on the disc will raise brake and brake fluid temperature.
- Check to see that the caliper holder shafts are not badly worn or stepped, and that the rubber friction boots are not damaged.
If the rubber friction boot is damaged, replace the rubber friction boot. To replace the friction boot, remove the pads and the caliper bracket.
If the caliper holder shaft is damage, replace the caliper bracket.
![](https://motoinstruction.ru/img/kawasaki/23/128821.jpg)