Front caliper disassembly
Remove:
- Front Caliper (see Front caliper removal in the Brakes chapter)
- Cotter Pin [A]
- Pin [B]
- Pads [C] (see Front brake pad removal in the Brakes chapter)
Push the piston in.
![](https://motoinstruction.ru/img/kawasaki/13/118643.jpg)
Remove:
- Pad Springs [A]
- Caliper Holder [B]
![](https://motoinstruction.ru/img/kawasaki/13/118644.jpg)
Using compressed air, remove the piston.
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.
lnsert a wooden board [A] 5 mm (0.2 in.) thick inside the caliper opening.
Apply compressed air [B] to the banjo bolt hole to allow the pistons [C] to protrude and stop at the wooden board.
![](https://motoinstruction.ru/img/kawasaki/13/118645.jpg)
Remove the wooden board and pull out the piston by hand.
★ If compressed air is not available, with the brake hose still attached, apply the brake lever to remove the pistons. The remaining process is as described above.
Remove:
- Dust Seals [A]
- Fluid Seals (Piston Seals) [B]
- Friction Boot [C]
- Bleed Valve
Caution! Immediately wash away any brake fluid that spills.
![](https://motoinstruction.ru/img/kawasaki/13/118646.jpg)
Front caliper assembly
Clean all parts other than the outer and inner pads.
Caution! For cleaning the parts, use only disc brake fluid, isopropyl alcohol, or ethyl alcohol.
Install the bleed valve [A] and the rubber cap [B].
Torque - Front Caliper Bleed Valve: 7.8 №m (0.80 kgf·m, 69 in·lb).
![](https://motoinstruction.ru/img/kawasaki/13/118647.jpg)
Replace the fluid seals [A] with new ones, apply brake fluid to them, and install them in the caliper body. Either side of the fluid seal may face outboard.
![](https://motoinstruction.ru/img/kawasaki/13/118648.jpg)
Check the dust seals [B] and replace them with new ones if they are damaged.
Apply brake fluid to the inside of the cylinders and to the outside of the pistons and push the pistons [A] into the cylinders.
Check the friction boot [B] and dust boot [C] and replace them with new ones if they are damaged.
Apply a thin coat of silicon grease to the holder shafts [D] and the holder holes.
![](https://motoinstruction.ru/img/kawasaki/13/118649.jpg)
Install the pad springs [A].
![](https://motoinstruction.ru/img/kawasaki/13/118650.jpg)
Install the pads (see Front brake pad installation in the Brakes chapter).
Wash the caliper with water to remove brake fluid and wipe it off.
Rear caliper disassembly
Remove:
- Rear Caliper (see Rear caliper removal in the Brakes chapter)
- Rear Brake Pad (see Rear brake pad removal in the Brakes chapter)
- Antirattle Spring [A]
Pull out the caliper holder [B].
![](https://motoinstruction.ru/img/kawasaki/13/118651.jpg)
Insert a wooden board [A] 5 mm (0.2 in.) thick inside the caliper opening.
Remove the pistons using the compressed air.
![](https://motoinstruction.ru/img/kawasaki/13/118652.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 pistons may crush your hand or fingers.
Remove the board and pull out the pistons [A] by hand.
Caution! Immediately wash away any brake fluid that spills.
![](https://motoinstruction.ru/img/kawasaki/13/118653.jpg)
Remove:
- Antirattle Spring [A]
- Dust Seals [B] and Fluid Seals [C]
- Rubber Friction Boots [D]
- Bleed Valves [E] and Rubber Caps [F]
![](https://motoinstruction.ru/img/kawasaki/13/118654.jpg)
Rear caliper assembly
Tighten the bleed valve.
Torque - Rear Caliper Bleed Valves: 7.8 N·m (0.80 kgf·m 69 in·lb).
It is recommended that the fluid seal (piston seal) which is removed, be replaced with a new one.
Replace the dust seals [A] if they are damaged.
![](https://motoinstruction.ru/img/kawasaki/13/118655.jpg)
Install the fluid seal [B]. Either side of the seal may face outboard.
Install the antirattle spring [A] in the caliper as shown.
![](https://motoinstruction.ru/img/kawasaki/13/118656.jpg)
Apply brake fluid to the cylinders, pistons, and fluid seals (piston seals), and push the pistons into the cylinders by hand. Take care that neither the cylinder nor the piston skirt gets scratched.
Replace the caliper holder shaft rubber friction boot [A] and dust boot [B] if they are damaged.
Apply a thin coat of silicone or PBC grease to the caliper holder shafts [C] and holder holes (Silicone or PBC grease is a special high temperature, water-resistance grease).
Install the pads (see Rear brake pad installation in the Brakes chapter).
![](https://motoinstruction.ru/img/kawasaki/13/118657.jpg)