New Pads in front, Brake Lever travel seems excessive.

[Daytona_Mike]

I've been bleeding this thing at the banjo's and the screws and tying the brake lever at night with a bungee.  I removed the master cylinder from handlebar to try to release any trapped air.   A short test and the bike stops just fine but the travel is still nearly reaching, if not touching, the grip.  (You know what just occurred to me as I typed this is that I installed larger grips on it the day I brought it home from the dealer.  There's probably an additional quarter inch on the radius of the grip.)  Today I try mass bombing.  I'm going to run a full pint of brake fluid through the system bleeding only at the screws and then tie it off overnight.  Whatever I get, I get.  I'll let you know.

Sounds like you might have  normal travel with old rubber brake lines.  Install 'life-time' stainless hoses from Murph and you will have a rock solid  feel more than stock hoses ever did.
This is  replacement info from the Kawasaki  Service Manual. How old are yours?

Brake hose - replace
Replace every 4 years

Master cylinder. Cup & dust seal
Replace every 2 years

Caliper piston seal & dust seal
Replace every 2 years

[turbojoe78]

I just put my front end back together, disassembled and cleaned my 4 pot Tokico calipers and attached the 2 s/s lines from Murf and bled the system.  I bled till I couldn't seem to get any more air out and yet the brake lever would still make it to the grip and felt spongy.

I zip tied the lever very tight against the grip yesterday and left it on for around 24 hours.  Today I cut the zip tie off and now the lever feels solid at about half way to the grip.

[Gitbox]

I'm curious. How did zip tying the lever fix your problem?

[turbojoe78]

My guess would be that it puts the master cylinder in a position that allows trapped air in the system to bleed up the lines and through the master cylinder to the reservoir.