Front Caliper Disassembly
Remove:
- Front Caliper (See Front Caliper Removal in the Brakes chapter)
- Brake Pads (See Front Brake Pad Removal in the Brakes chapter)
- Using compressed air, remove the pistons.
Cover the piston area with a clean, thick cloth [A].
Blow compressed air [B] into the hole for the banjo bolt to remove the piston.
![](https://motoinstruction.ru/img/kawasaki/23/128189.jpg)
Warning: To avoid serious injury, never place your fingers or palm in front of the piston. If you apply compressed air into the caliper, the piston may crush your hand or fingers.
Pull out the pistons by hand.
- Remove the dust seals [A] and fluid seals [B].
- Remove the bleed valve [C] and rubber cap [D].
![](https://motoinstruction.ru/img/kawasaki/23/128190.jpg)
Note: If compressed air is not available, with the brake hose still attached, apply the brake lever to remove the piston. The remaining process is as described above.
Front Caliper Assembly
- Clean the caliper parts except for the pads.
Caution: For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol.
- Install the bleed valve and rubber cap.
Torque - Bleed Valve: 7.8 Nm (0.80 kgf·m, 69 in·lb)
- Replace the fluid seals [A] with new ones.
Apply brake fluid to the fluid seals, and install them into the cylinders by hand.
![](https://motoinstruction.ru/img/kawasaki/23/128191.jpg)
- Replace the dust seals [B] with new ones if they are damaged.
Apply brake fluid to the dust seals, and install them into the cylinders by hand.
- Apply brake fluid to the outside of the pistons, and push them into each cylinder by hand.
- Check the shaft rubber friction boot [A] and the dust cover [B] replace them with new ones if they are damaged.
- Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to the caliper holder shafts [C] and holder holes [D] (PBC is a special high-temperature, water-resistance grease).
![](https://motoinstruction.ru/img/kawasaki/23/128192.jpg)
- Install the anti-rattle spring [A].
- Install the pads (See Front Brake Pad Installation in the Brakes chapter).
- Wipe up any spilled brake fluid on the caliper with wet cloth.
![](https://motoinstruction.ru/img/kawasaki/23/128193.jpg)
Rear Caliper Disassembly
- Remove the rear caliper (See Rear Caliper Removal in the Brakes chapter).
- Remove the pads and anti-rattle spring (See Rear Brake Pad Removal in the Brakes chapter).
- Using compressed air, remove the piston.
Cover the piston area with a clean, thick cloth [B].
Blow compressed air [A] into the hole for the banjo bolt to remove the piston.
![](https://motoinstruction.ru/img/kawasaki/23/128194.jpg)
Warning: To avoid serious injury, never place your fingers or palm inside the caliper opening. If you apply compressed air into the caliper, the piston may crush your hand or fingers.
- Remove the dust seal and fluid seal.
- Remove the bleed valve and rubber cap.
Note: If compressed air is not available, with the brake hose still attached, apply the brake pedal to remove the piston. The remaining process is as described above.
Rear Caliper Assembly
- Clean the caliper parts except for the pads.
Caution: For cleaning of the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol.
- Install the bleed valve and rubber cap.
Torque - Bleed Valve: 7.8 N·m (0.80 kgf·m, 69 in·lb)
- Replace the fluid seal [A] with a new one.
Apply brake fluid to the fluid seal, and install it into the cylinder by hand.
- Replace the dust seal [B] with a new one if it is damaged. OApply brake fluid to the dust seal, and install it into the cylinder by hand.
![](https://motoinstruction.ru/img/kawasaki/23/128195.jpg)
- Apply brake fluid to the outside of the piston, and push it into the cylinder by hand.
- Replace the shaft rubber friction boot [A] and dust boot [B] if they are damaged.
- Apply a thin coat of PBC (Poly Butyl Cuprysil) grease to the caliper holder shafts [C] and holder holes [D] (PBC is a special high-temperature, water-resistance grease).
![](https://motoinstruction.ru/img/kawasaki/23/128196.jpg)
- Install the anti-rattle spring [A] in the caliper as shown.
- Install the pads (See Rear Brake Pad Installation in the Brakes chapter).
- Wipe up any spilled brake fluid on the caliper with wet cloth.