Kawasaki Ninja Service Manual: KIBS Hydraulic Unit Removal

Kawasaki Ninja Service Manual / Brakes / KIBS (Equipped Models) / KIBS Hydraulic Unit Removal

NOTICE

The KIBS hydraulic unit [A] has been adjusted and set with precision at the factory. Therefore, it should be handled carefully, never struck sharply, as with a hammer, or allowed to fall on a hard surface.

Be careful not to get water or mud on the KIBS hydraulic unit.

Drain the brake fluid from the front and rear brake lines.

Drain the brake fluid through the bleed valve by pumping the brake lever and pedal.

KIBS Hydraulic Unit Removal

Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Right Lower Fairing (see Lower Fairing Removal in the Frame chapter)
Remove: Bolts [A] Cover [B]

Clear the projection [C] from the bracket.

Clean the KIBS hydraulic unit.

KIBS Hydraulic Unit Removal

NOTICE

Clean all fittings on the KIBS hydraulic unit and the rear master cylinder because dirt around the banjo bolts could contaminate the brake fluid in the line during removal/installation.

Spread over a shop towel around the KIBS hydraulic unit before removing the brake line so that brake fluid does not leak on the parts.

Pull the lever [A] backward to disconnect the KIBS hydraulic unit connector [B].

KIBS Hydraulic Unit Removal

Loosen the brake pipe joint nuts [A] with the flare nut wrench.
Take the KIBS hydraulic unit [B] together with the bracket off the brake pipes.

NOTICE

Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately.

KIBS Hydraulic Unit Removal

NOTE

Remove the brake hoses and pipes according to each assembly of the exploded view.

Remove the bolts [A].

KIBS Hydraulic Unit Removal

Remove: Quick Rivet [A] Bolt [B]

KIBS Hydraulic Unit Removal

Remove the bolt [A].
Take the KIBS hydraulic unit [B] off the bracket [C].

NOTICE

The KIBS hydraulic unit has been adjusted and set with precision at the factory. Do not try to disassemble and repair the KIBS hydraulic unit.

KIBS Hydraulic Unit Removal

ABS and KIBS Indicator Lights (LED) Inspection

In this model, the ABS indicator light (LED) [A] and KIBS indicator light (LED) [B] go on or blink by the data sent from the KIBS hydraulic unit. Refer to the Meter Unit Inspection in the Electr ...

KIBS Hydraulic Unit Installation

NOTICE Brake fluid quickly ruins painted plastic surfaces; any spilled fluid should be completely washed away immediately. Install the KIBS hydraulic unit together with the bracket. Before in ...

Other materials:

Terminal Numbers of ECU Connectors
1. Subthrottle Valve Actuator: Y/BK 2. Subthrottle Valve Actuator: BK/O 3. Unused 4. Front Wheel Rotation Sensor Signal: G/Y 5. Unused 6. Starter Lockout Switch: R/G 7. Gear Position Switch: G/R 8. Crankshaft Sensor (–): BK 9. Power Supply to Sensors: BL 10. Unused 11. Intake Air Pre ...

Coolant Level Inspection
NOTE Check the level when the engine is cold (room or ambient temperature). Check the coolant level in the reserve tank [A] with the motorcycle held perpendicular (Do not use the sidestand). If the coolant level is lower than the “L” level line [B], remove the upper fairing assembly (s ...

Throttle Body Assy Holder Installation
Be sure to install the new O-rings [A]. Using a high flash-point solvent, clean off any oil or dirt that may be on the silicone sealant coating area. Dry them with a clean cloth. Apply silicone sealant to any two positions of the new O -ring. Sealant - Liquid Gasket, TB1211F: 92104-0 ...