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:

Rear Wheel Removal
Raise the rear wheel off the ground with the stand [A]. Remove: Cotter Pin [A] Rear Axle Nut [B] Washer [C] Rear Axle [D] (from Right Side) Remove the rear wheel rotation sensor from the caliper bracket (see Rear Wheel Rotation Sensor Removal in the Brakes chapter). ...

Idle Speed Inspection
Start the engine and warm it up thoroughly. With the engine idling, turn the handlebar to both sides [A]. If handlebar movement changes the idle speed, the throttle cables may be improperly adjusted or incorrectly routed, or damaged. Be sure to correct any of these conditions before rid ...

Specifications
Connecting Rod Big End Bearing Insert Selection Crankshaft Main Bearing Insert Selection *: The bearing inserts for Nos. 2 and 4 journals have an oil groove, respectively. ...