Kawasaki Ninja Service Manual: 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.

• 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.

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].

• 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.

NOTE

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

• Remove the bolts [A].

• Remove: Quick Rivet [A] Bolt [B]

• 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.