Kawasaki Motorcycle Ninja ZX-6R / Ninja ZX-6R ABS. Service Manual (2013 year)

BRAKES 12-13

Brake Lever, Brake Pedal

•

Remove:

Cotter Pin [A]
Joint Pin [B]
Rear Brake Light Switch Spring [C]
Return Spring [D]

•

Remove the brake pedal mounting bolt [E] and take out
the brake pedal.

Brake Pedal Installation

•

Apply grease to the footpeg pivot shaft [A].

•

Install:

Bushing [B]
Brake Pedal [C]

•

Apply a non-permanent locking agent to the threads of
the brake pedal mounting bolt [D], and tighten it.

Torque - Brake Pedal Mounting Bolt: 34 N·m (3.5 kgf·m, 25

ft·lb)

•

Hook the return spring [A] on the brake pedal and front
footpeg bracket [B] as shown.

•

Hook the rear brake light switch spring [C] on the switch
and return spring as shown.

•

Replace the cotter pin [A] with a new one.

•

Insert the cotter pin and bend the pin ends [B].

12-14 BRAKES

Brake Lever, Brake Pedal

•

Install the front footpeg bracket.

•

Apply a non-permanent locking agent to the threads of
the front footpeg bracket bolts, and tighten them.

Torque - Front Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m,

18 ft·lb)

•

Install the rear master cylinder [A] and foot guard.

NOTE

○

Depress the brake pedal [B] and then align the holes of
the master cylinder.

○

After installation, check that the rear brake light switch
spring is hooked on the return spring.

•

Apply a non-permanent locking agent to the threads of
the front bracket bolts, and tighten them.

Torque - Rear Master Cylinder Mounting Bolts: 25 N·m (2.5

kgf·m, 18 ft·lb)

•

Check the brake pedal position (see Brake Pedal Position
Inspection).

BRAKES 12-15

Calipers

Front Caliper Removal

•

Remove:

Bolt [A]
Front Wheel Rotation Sensor [B]

•

Loosen the banjo bolt [C] at the brake hose lower end,
and tighten it loosely.

•

Remove the caliper mounting bolts [D], and detach the
caliper [E] from the disc.

•

Unscrew the banjo bolt and remove the brake hose from
the caliper (see Brake Hose and Pipe Replacement in the
Periodic Maintenance chapter).

NOTICE

Immediately wash away any brake fluid that spills.

Rear Caliper Removal

•

Remove:

Bolt [A]
Rear Wheel Rotation Sensor [B]

•

Loosen the banjo bolt [C] at the brake hose lower end,
and tighten it loosely.

•

Loosen the rear caliper pin bolt [D].

•

Remove the rear wheel (see Rear Wheel Removal in the
Wheels/Tires chapter).

•

Unscrew the banjo bolt and remove the brake hoses from
the caliper (see Brake Hose and Pipe Replacement in the
Periodic Maintenance chapter).

NOTICE

Immediately wash away any brake fluid that spills.

12-16 BRAKES

Calipers

Caliper Installation

•

Install the caliper and brake hose lower end.

○

For the front caliper, be sure to install the collars [A].

○

Replace the washers on each side of hose fitting with new
ones.

○

Touch the brake hoses to the stopper of the caliper.

•

Tighten:

Torque - Front Caliper Mounting Bolts: 34 N·m (3.5 kgf·m,

25 ft·lb)

Rear Caliper Pin Bolt: 27 N·m (2.8 kgf·m, 20 ft·lb)
Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18

ft·lb)

•

Check the fluid level in the brake reservoirs.

•

Bleed the brake line (see Brake Line Bleeding).

•

Check the brake for good braking power, no brake drag,
and no fluid leakage.

WARNING

After servicing, it takes several applications of the
brake lever or pedal before the brake pads contact
the disc, which could result in increased stopping
distance and cause an accident resulting in injury
or death. Do not attempt to ride the motorcycle until
a firm brake lever or pedal is obtained by pumping
the lever or pedal until the pads are against the disc.

Front Caliper Disassembly

•

Refer to the Caliper Rubber Parts Replacement in the Pe-
riodic Maintenance chapter.

Front Caliper Assembly

•

Refer to the Caliper Rubber Parts Replacement in the Pe-
riodic Maintenance chapter.

Rear Caliper Disassembly

•

Refer to the Caliper Rubber Parts Replacement in the Pe-
riodic Maintenance chapter.

Rear Caliper Assembly

•

Refer to the Caliper Rubber Parts Replacement in the Pe-
riodic Maintenance chapter.

BRAKES 12-17

Calipers

Caliper Fluid Seal Damage Inspection

The fluid seal (piston seal) [A] is placed around the pis-

ton to maintain clearance between the pad and the disc. If
the seal is in a poor condition, it could lead the pad to wear
excessively or the brake to drag, which may cause the tem-
perature of the discs or the brake fluid to increase.

•

Replace the fluid seal if it exhibits any of the conditions
listed below.

○

Brake fluid leakage around the pad.

○

Brakes overheat.

○

Considerable difference in inner and outer pad wear.

○

Seal and piston are stuck together.
If the fluid seal is replaced, replace the dust seal [B] as
well. Also, replace all seals every other time the pads are
changed.

Caliper Dust Seal Damage Inspection

•

Check that the dust seals [A] are not cracked, worn,
swollen, or otherwise damaged.
If they show any damage, replace the dust seals with new
ones.

Pistons [B]
Fluid Seals [C]

Rear Caliper Dust Boot and Friction Boot Damage
Inspection

•

Check that the dust boot [A] and friction boot [B] are not
cracked, worn, swollen, or otherwise damaged.
If they show any damage, replace it.

12-18 BRAKES

Calipers

Caliper Piston and Cylinder Damage Inspection

•

Visually inspect the pistons [A] and cylinder surfaces [B].
Replace the caliper if the cylinder and piston are badly
scores or rusty.

Rear Caliper Holder Shaft Wear Inspection

The caliper body must slide smoothly on the caliper holder

shafts [A]. If the body does not slide smoothly, one pad will
wear more than the other, pad wear will increase, and con-
stant drag on the disc will raise brake and brake fluid tem-
perature.

•

Check to see that the caliper holder shafts are not badly
worn or stepped, and that the rubber boots are not dam-
aged.
If the rubber boot is damaged, replace the rubber boot. To
replace the rubber boot, remove the pads and the caliper
bracket.
If the caliper holder shaft is damage, replace the caliper
bracket.

BRAKES 12-19

Brake Pads

Front Brake Pad Removal

•

Loosen the pad pins [A].

•

Remove the front caliper with the hose installed (see Front
Caliper Removal).

•

Remove:

Pad Pins
Brake Pads

Front Brake Pad Installation

•

Check that the pad spring [A] is in place on the caliper.

•

Push the caliper pistons in by hand as far as they will go.

•

Install the brake pads [A] on the pad spring correctly.

○

Fit the pad into the groove of the caliper.

•

Tighten the pad pins temporarily.

○

Push down the pin holder [A] and insert the pad pin [B].

•

Install the front caliper (see Caliper Installation).

•

Tighten:

Torque - Front Brake Pad Pins: 17 N·m (1.7 kgf·m, 13 ft·lb)

WARNING

After servicing, it takes several applications of the
brake lever before the brake pads contact the disc,
which could result in increased stopping distance
and cause an accident resulting in injury or death.
Do not attempt to ride the motorcycle until a firm
brake lever is obtained by pumping the lever until
the pads are against the disc.

12-20 BRAKES

Brake Pads

Rear Brake Pad Removal

•

Remove:

Pad Pin Plug [A]
Pad Pin [B]
Brake Pads [C]

Rear Brake Pad Installation

•

Check that the pad spring is in place on the caliper.

•

Push the caliper piston in as far as it will go.

•

Install the piston side pad [A] first, and then another pad.

○

Fit the brake pad end into the recess [B] of the caliper
bracket.

•

Install the pad pin and the plug.

•

Tighten:

Torque - Rear Brake Pad Pin: 17 N·m (1.7 kgf·m, 13 ft·lb)

Rear Brake Pad Pin Plug: 2.45 N·m (0.25 kgf·m, 22

in·lb)

WARNING

After servicing, it takes several applications of the
brake pedal before the brake pads contact the disc,
which could result in increased stopping distance
and cause an accident resulting in injury or death.
Do not attempt to ride the motorcycle until a firm
brake pedal is obtained by pumping the pedal until
the pads are against the disc.

Brake Pad Wear Inspection

•

Refer to the Brake Pad Wear Inspection in the Periodic
Maintenance chapter.

BRAKES 12-21

Master Cylinder

Front Master Cylinder Removal

•

Remove the reservoir mounting bolt and nut [A].

•

Unscrew the banjo bolt [A] and remove the brake hose
from the master cylinder (see Brake Hose and Pipe Re-
placement in the Periodic Maintenance chapter).

•

Unscrew the clamp bolts [B], and take off the master cylin-
der as an assembly with the reservoir, brake lever, and
front brake light switch installed.

•

Disconnect the front brake light switch connector [C].

NOTICE

Immediately wash away any brake fluid that spills.

•

Remove:

Brake Lever Pivot Bolt [A] and Locknut [B]
Brake Lever [C]
Clamp [D]
Brake Hose [E]
Front Brake Light Switch [F]

Front Master Cylinder Installation

•

Apply silicone grease to the sliding surface of the brake
lever pivot bolt.

•

Tighten:

Torque - Brake Lever Pivot Bolt: 1.0 N·m (0.10 kgf·m, 8.9

in·lb)

Brake Lever Pivot Bolt Locknut: 5.9 N·m (0.60

kgf·m, 52 in·lb)

•

Install the front brake light switch.

•

Tighten:

Torque - Front Brake Light Switch Screw: 1.2 N·m (0.12

kgf·m, 11 in·lb)

•

Install the front brake reservoir to the front master cylinder.

12-22 BRAKES

Master Cylinder

•

Install the master cylinder clamp [A] so that the arrow
mark [B] faces upward.

•

Set the front master cylinder to match its mating surface
[A] to the punch mark [B] of the handlebar.

•

Tighten the upper clamp bolt first, and then the lower
clamp bolt.

Torque - Front Master Cylinder Clamp Bolts: 11 N·m (1.1

kgf·m, 97 in·lb)

•

Connect the front brake light switch connector [A] as
shown.

Left Side View [B]
Front [C]

•

Replace the washers that are on each side of the hose
fitting with new ones.

•

Install the brake hose [D].

○

Touch the brake hose to the stopper of the front master
cylinder.

•

Tighten:

Torque - Brake Hose Banjo Bolts: 25 N·m (2.5 kgf·m, 18

ft·lb)

•

Tighten the front brake reservoir mounting nut.

•

Bleed the brake line (see Brake Line Bleeding).

•

Check the brake for good braking power, no brake drag,
and no fluid leakage.

Rear Master Cylinder Removal

•

Unscrew the brake hose banjo bolt [A] and remove the
brake hose (see Brake Hose and Pipe Replacement in
the Periodic Maintenance chapter).

NOTICE

Immediately wash away any brake fluid that spills.

•

Remove:

Rear Master Cylinder Mounting Bolts [B]
Foot Guard [C]
Front Footpeg Bracket Bolts [D]

BRAKES 12-23

Master Cylinder

•

Remove:

Cotter Pin [A]
Joint Pin [B]

•

Slide the reservoir hose lower end clamp [A].

•

Remove the reservoir hose lower end [B], and drain the
brake fluid into a container.

Rear Master Cylinder Installation

•

Replace the cotter pin [A] with a new one.

•

Insert the cotter pin and bend the pin ends [B].

•

Install the reservoir hose lower end to the rear master
cylinder.

•

Apply a non-permanent locking agent to the threads of
the front footpeg bracket bolts.

•

Tighten:

Torque - Front Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m,

18 ft·lb)

Rear Master Cylinder Mounting Bolts: 25 N·m (2.5

kgf·m, 18 ft·lb)

NOTE

○

Depress the brake pedal [A] and then align the holes of
the master cylinder [B].

○

After installation, check that the rear brake light switch
spring is hooked on the return spring.

•

Replace the washers that are on each side of hose fitting
with new ones.

•

Install the brake hose.

○

Touch the brake hose to the stopper of the rear master
cylinder.

•

Tighten:

Torque - Brake Hose Banjo Bolt: 25 N·m (2.5 kgf·m, 18 ft·lb)

•

Bleed the brake line (see Brake Line Bleeding).

•

Check the brake for good braking power, no brake drag,
and no fluid leakage.

12-24 BRAKES

Master Cylinder

Front Master Cylinder Disassembly

•

Refer to the Master Cylinder Rubber Parts Replacement
in the Periodic Maintenance chapter.

Rear Master Cylinder Disassembly

•

Refer to the Master Cylinder Rubber Parts Replacement
in the Periodic Maintenance chapter.

Master Cylinder Assembly

•

Refer to the Master Cylinder Rubber Parts Replacement
in the Periodic Maintenance chapter.

Master Cylinder Inspection (Visual Inspection)

•

Remove the master cylinders (see Front/Rear Master
Cylinder Removal).

•

Disassemble the front and rear master cylinders (see
Master Cylinder Rubber Parts Replacement in the Peri-
odic Maintenance chapter).

•

Check that there are no scratches, rust or pitting on the
inner wall [A] of each master cylinder and on the outside
of each piston [B].
If a master cylinder or piston shows any damage, replace
them.

•

Inspect the primary cup [C] and secondary cup [D].
If a cup is worn, damaged softened (rotted), or swollen,
the piston assembly should be replaced to renew the
cups.
If fluid leakage is noted at the brake lever, the piston as-
sembly should be replaced to renew the cups.

•

Check the dust covers [E] for damage.
If they are damaged, replace them.

•

Check the piston return springs [F] for any damage.
If the springs are damaged, replace them.

•

Check that relief port [G] and supply port [H] are not
plugged.
If the relief port becomes plugged, the brake pads will
drag on the disc. Blow the ports clean with compressed
air.

Front Master Cylinder [I]
Rear Master Cylinder [J]

BRAKES 12-25

Brake Disc

Brake Disc Removal

•

Remove the wheels (see Front/Rear Wheel Removal in
the Wheels/Tires chapter).

•

Remove the brake disc mounting bolts [A], and take off
the disc [B].

•

Remove the wheel rotation sensor rotor [C].

Brake Disc Installation

•

Replace the gaskets with new ones.

•

Install the brake disc on the wheel so that the marked side
[A] faces out.

Front Brake Discs [B]
Rear Brake Disc [C]

•

Install the wheel rotation sensor rotor on the brake disc.

○

When installing the rear wheel rotation sensor rotor, the
bended end faces to disc side.

•

Apply a non-permanent locking agent to the threads of
the brake disc mounting bolts.

•

Tighten:

Torque - Brake Disc Mounting Bolts: 27 N·m (2.8 kgf·m, 20

ft·lb)

Brake Disc Wear Inspection

•

Measure the thickness of each disc [A] at the point where
it has worn the most.
If the disc has worn past the service limit, replace it.

Measuring Area [B]

Brake Discs Thickness

Standard:

Front

4.8

∼

5.2 mm (0.19

∼

0.20 in.)

Rear

4.8

∼

5.2 mm (0.19

∼

0.20 in.)

Service Limit:

Front

4.5 mm (0.18 in.)

Rear

4.5 mm (0.18 in.)

12-26 BRAKES

Brake Disc

Brake Disc Warp Inspection

•

Raise the wheel off the ground with jack.

Special Tools - Jack: 57001-1238

Jack Attachment: 57001-1608

○

For front disc inspection, turn the handlebar fully to one
side.

•

Set up a dial gauge against the disc [A] as shown and
measure disc runout, while turning [B] the wheel by hand.
If runout exceeds the service limit, replace the disc.

Disc Runout

Standard:

Front

TIR 0.15 mm (0.006 in.) or less

Rear

TIR 0.20 mm (0.008 in.) or less

Service Limit: TIR 0.3 mm (0.01 in.)

BRAKES 12-27

Brake Fluid

Brake Fluid Level Inspection

•

Refer to the Brake Fluid Level Inspection in the Periodic
Maintenance chapter.

Brake Fluid Change

•

Refer to the Brake Fluid Change in the Periodic Mainte-
nance chapter.

Brake Line Bleeding

The brake fluid has a very low compression coefficient so

that almost all the movement of the brake lever or pedal
is transmitted directly to the caliper for braking action. Air,
however, is easily compressed. When air enters the brake
lines, brake lever or pedal movement will be partially used
in compressing the air. This will make the lever or pedal feel
spongy, and there will be a loss in braking power.

WARNING

Air in the brake lines diminish braking performance
and can cause an accident resulting in injury or
death.

If the brake lever or pedal has a soft or

"spongy" feeling mushy when it is applied, there
might be air in the brake lines or the brake may be
defective. Do not operate the vehicle and service
the brake system immediately.

NOTE

○

The procedure to bleed the front brake line is as follows.
Bleeding the rear brake line is the same as for the front
brake.

•

Remove:

Screw [A]
Stopper [B]
Front Brake Reservoir Cap [C]

•

Remove:

Bolt [A]
Rear Brake Reservoir Cap [B]

12-28 BRAKES

Brake Fluid

•

Remove:

Diaphragm Plate
Diaphragm

•

Fill the reservoir with fresh brake fluid to the upper level
line in the reservoir.

•

Slowly pump the brake lever several times until no air
bubbles can be seen rising up through the fluid from the
holes at the bottom of the reservoir.

•

Remove the rubber cap [A] from the bleed valve on the
front master cylinder.

•

Attach a clear plastic hose [B] to the bleed valve, and run
the other end of the hose into a container.

•

Bleed the brake line and the master cylinder.

○

Repeat this operation until no more air can be seen com-
ing out into the plastic hose.
1. Pump the brake lever until it becomes hard, and apply

the brake and hold it [A].

2. Quickly open and close [B] the bleed valve while hold-

ing the brake applied.

3. Release the brake [C].

NOTE

○

The fluid level must be checked often during the bleed-
ing operation and replenished with fresh brake fluid as
necessary. If the fluid in the reservoir runs completely
out any time during bleeding, the bleeding operation
must be done over again from the beginning since air
will have entered the line.

•

Remove the clear plastic hose.

•

Tighten the bleed valve, and install the rubber cap.

Torque - Front Master Cylinder Bleed Valve: 5.4 N·m (0.55

kgf·m, 48 in·lb)

•

Remove the rubber cap [A] from the bleed valve on the
caliper.

•

Attach a clear plastic hose [B] to the bleed valve, and run
the other end of the hose into a container.

BRAKES 12-29

Brake Fluid

•

Bleed the brake line and the caliper.

○

Repeat this operation until no more air can be seen com-
ing out into the plastic hose.
1. Pump the brake lever until it becomes hard, and apply

the brake and hold it [A].

2. Quickly open and close [B] the bleed valve while hold-

ing the brake applied.

3. Release the brake [C].

NOTE

○

Tap the brake hose lightly from the caliper to the reser-
voir for more complete bleeding.

○

Front Brake: First bleeding the right caliper then repeat
the above steps for the left caliper.

•

Remove the clear plastic hose.

•

Install:

Diaphragm
Diaphragm Plate
Front Brake Reservoir Cap

•

Follow the procedure below to install the front/rear brake
fluid reservoir cap correctly.

○

First, tighten the brake fluid reservoir cap [B] clockwise
[C] by hand until slight resistance is felt indicating that
the cap is seated on the reservoir body, then tighten the
cap an additional 1/6 turn [D] while holding the brake fluid
reservoir body [A].

•

Install the stopper and screw.

•

Tighten:

Torque - Front Brake Reservoir Cap Stopper Screw: 1.2

N·m (0.12 kgf·m, 11 in·lb)

•

Install the rear brake reservoir, and tighten the bolt.

•

Tighten the bleed valve, and install the rubber cap.

Torque - Bleed Valves: 7.8 N·m (0.80 kgf·m, 69 in·lb)

•

Check the fluid level (see Brake Fluid Level Inspection in
the Periodic Maintenance chapter).

•

After bleeding is done, check the brake for good braking
power, no brake drag, and no fluid leakage.

12-30 BRAKES

Brake Fluid

WARNING

When working with the disc brake, observe the pre-
cautions listed below.

•

Never reuse old brake fluid.

•

Do not use fluid from a container that has been left
unsealed or that has been open for a long time.

•

Do not mix two types and brands of fluid for use
in the brake. This lowers the brake fluid boiling
point and could cause the brake to be ineffective.
It may also cause the rubber brake parts to dete-
riorate.

•

Don’t leave the reservoir cap off for any length of
time to avoid moisture contamination of the fluid.

•

Don’t change the fluid in the rain or when a strong
wind is blowing.

•

Except for the disc pads and disc, use only disc
brake fluid, isopropyl alcohol, or ethyl alcohol for
cleaning of the brake parts. Do not use any other
fluid for cleaning these parts. Gasoline, engine
oil, or any other petroleum distillate will cause de-
terioration of the rubber parts. Oil spilled on any
part will be difficult to wash off completely and will
eventually deteriorate the rubber used in the disc
brake.

•

When handling the disc pads or disc, be careful
that no disc brake fluid or any oil gets on them.
Clean off any fluid or oil that inadvertently gets on
the pads or disc with a high flash-point solvent.
Do not use one which will leave an oily residue.
Replace the pads with new ones if they cannot be
cleaned satisfactorily.

•

Brake fluid quickly ruins painted surfaces; any
spilled fluid should be completely wiped up im-
mediately.

•

If any of the brake line fittings or the bleed valve is
opened at any time, the AIR MUST BE BLED FROM
THE BRAKE LINE.

12-34 BRAKES

KIBS (Equipped Models)

KIBS System Circuit

1. Ignition Switch
2. Front Brake Light Switch
3. ECU
4. Rear Wheel Rotation Sensor
5. Rear Brake Light Switch
6. Frame Ground 5
7. Frame Ground 4
8. Engine Ground
9. Battery 12 V 8 Ah

10. Starter Relay

11. Main Fuse 30 A

12. Fuse Box 3

13. KIBS Solenoid Valve Relay Fuse 15 A
14. KIBS Motor Relay Fuse 25 A
15. KIBS Kawasaki Self-diagnosis System Connector
16. KIBS Hydraulic Unit
17. Fuse Box 1
18. Brake Light/Horn Fuse 7.5 A
19. Ignition Fuse 15 A
20. Meter Unit
21. Yellow ABS Indicator Light (LED)
22. Yellow Warning Indicator Light (LED)
23. Joint Connector E
24. Front Wheel Rotation Sensor

○

Color Codes:

BK: Black

BL: Blue

BR: Brown

CH: Chocolate

DG: Dark Green

G: Green

GY: Gray

LB: Light Blue

LG: Light Green

O: Orange

P: Pink

PU: Purple

R: Red

V: Violet

W: White

Y: Yellow

12-36 BRAKES

KIBS (Equipped Models)

KIBS Servicing Precautions

There are a number of important precautions that should

be followed servicing the KIBS.

○

This KIBS is designed to be used with a 12 V sealed bat-
tery as its power source. Do not use any other battery
except for a 12 V sealed battery as a power source.

○

Do not reverse the battery cable connections. This will
damage the KIBS hydraulic unit.

○

To prevent damage to the KIBS parts, do not discon-
nect the battery cables or any other electrical connections
when the ignition switch is on or while the engine is run-
ning.

○

Take care not to short the leads that are directly con-
nected to the battery positive (+) terminal to the chassis
ground.

○

Do not turn the ignition switch on while any of the KIBS
electrical connectors are disconnected. The KIBS hy-
draulic unit memorizes service codes.

○

Do not spray water on the electrical parts, KIBS parts,
connectors, leads and wiring.

○

If a transceiver is installed on the motorcycle, make sure
that the operation of the KIBS is not influenced by electric
wave radiated from the antenna. Locate the antenna as
far as possible away from the KIBS hydraulic unit.

○

Whenever the KIBS electrical connections are to be dis-
connected, first turn off the ignition switch.

○

The KIBS parts should never be struck sharply, as with
a hammer, or allowed to fall on a hard surface. Such a
shock to the parts can damage them.

○

The KIBS parts cannot be disassembled. Even if a fault
is found, do not try to disassemble and repair the KIBS
parts, replace it.

○

The KIBS has many brake lines, pipes, and leads. And
the KIBS cannot detect problems with the conventional
braking system (brake disc wear, unevenly worn brake
pad, and other mechanical faults). To prevent trouble,
check the brake lines and pipes for correct routing and
connection, the wiring for correct routing, and the brakes
for proper braking power. Be sure to check for fluid leak-
age, and bleed the brake line thoroughly.

WARNING

Air in the brake lines diminish braking performance
and can cause an accident resulting in injury or
death. If any of the brake line fittings, including the
KIBS hydraulic unit joint nuts, or the bleed valve is
opened at any time, the air must be bled completely
from the brake line. If the brake lever has a soft
or "spongy" feeling mushy when it is applied, there
might be air in the brake lines or the brake may be
defective. Do not operate the vehicle and service
the brake system immediately.

NOTICE

Do not ride the motorcycle with air in the brake line,
or the KIBS could malfunction.

BRAKES 12-37

KIBS (Equipped Models)

○

The yellow ABS indicator light (LED) [A] and yellow warn-
ing indicator light (LED)/KIBS warning symbol [B] may
light if the tire pressure is incorrect, a non-recommended
tire is installed, or the wheel is deformed. If the indica-
tor light lights, remedy the problem and clear the service
code.

WARNING

Use of non-recommended tires may cause malfunc-
tioning of KIBS and can lead to extended braking
distance resulting in an accident causing serious
injury or death. Always use recommended stan-
dard tires for this motorcycle.

○

The yellow ABS indicator light (LED) may come on if the
engine is run with the motorcycle on a stand and the trans-
mission in gear. If the indicator light comes on, just turn
the ignition switch off, then clear service code b 42, which
indicates a “Faulty front wheel rotation sensor”.

○

When the KIBS operates, the KIBS makes noise and the
rider feels the reaction force on the brake lever and brake
pedal. This is a normal condition. It informs the rider that
the KIBS is operating normally.

○

Service codes detected once by the KIBS hydraulic unit
will be memorized in the KIBS hydraulic unit.

○

A fully charged battery is a must for conducting reliable
self-diagnosis. Test run the motorcycle at a speed of more
than 20 km/h (12 mph) to see that the yellow ABS indica-
tor light (LED) and yellow warning indicator light (LED) do
not come on. Finally, test run the motorcycle at a speed
of more than 30 km/h (20 mph) and brake suddenly to see
that the motorcycle stops without loss of steering control
and the KIBS operates normally (The reaction force gen-
erated is felt in the brake lever and pedal.). This com-
pletes the final inspection.

12-38 BRAKES

KIBS (Equipped Models)

KIBS Troubleshooting Outline

When an abnormality in the system occurs, the yellow

ABS indicator light (LED) and yellow warning indicator light
(LED) light up and the KIBS warning symbol are displayed
on the LCD (Liquid Crystal Display) to alert the rider. In
addition, the nature of the fault is stored in the memory
of the KIBS hydraulic unit and FI ECU, and when in the
self-diagnosis mode, the service code [A] is displayed on
the LCD by the “b” and the number of two digits. When re-
pair has been done, the both warning indicator lights (LED)
and KIBS warning symbol go off and service codes are not
displayed. But the service codes stored in memory of the
KIBS hydraulic unit ECU and FI ECU are not erased to pre-
serve the problem history.

When, due to a malfunction, the yellow ABS indicator

light (LED) and yellow warning indicator light (LED) remain
lit, get a thorough understanding of the background be-
fore starting the repair work. Ask the rider about the con-
ditions [B] under which the problem occurred and try to
determine the cause [C]. Do not rely solely on the KIBS
and DFI self-diagnosis function, use common sense; check
the brakes for proper braking power, and brake fluid level,
search for leaks, etc.

Even when the KIBS and DFI are operating normally, the

yellow ABS indicator light (LED) and yellow warning indica-
tor light (LED) may light up and the KIBS warning symbol
are displayed on the LCD under the conditions listed below.
Turn the ignition switch off to go off the indicator lights and
the KIBS warning symbol.

○

After continuous riding on a rough road.

○

When the engine is started with the stand raised and the
transmission engaged, and the rear wheel turns.

○

When accelerating so abruptly that the front wheel leaves
the ground.

○

When the KIBS has been subjected to strong electrical
interference.

○

When tire pressure is abnormal. Adjust tire pressure.

○

When a tire different in size from the standard size is being
used. Replace with standard size.

○

When the wheel is deformed. Replace the wheel.

Much of the KIBS troubleshooting work consists of con-

firming continuity of the wiring. The KIBS parts are assem-
bled and adjusted by the manufacturer, so there is no need
to disassemble or repair them. Replace the KIBS hydraulic
unit.

The basic troubleshooting procedures are listed below.

•

Carry out pre-diagnosis inspections as a preliminary in-
spection.

•

Determine the fault using the self-diagnosis function.

•

Check wiring and connections from the KIBS hydraulic
unit connector to the suspected faulty KIBS part, using
the hand tester.

Special Tool - Hand Tester: 57001-1394

BRAKES 12-39

KIBS (Equipped Models)

•

Visually inspect the wiring for signs of burning or fraying.
If any wiring is poor, replace the damaged wiring.

•

Pull each connector apart and inspect it for corrosion, dirt
and damage.
If the connector is corroded or dirty, clean it carefully. If it
is damaged, replace it.

•

Check the wiring for continuity.

○

Use the wiring diagram to find the ends of the lead which
is suspected of being a problem.

○

Connect the hand tester between the ends of the leads.

Special Tool - Hand Tester: 57001-1394

○

Set the tester to the × 1

Ω

range, and read the tester.

If the tester does not read 0

Ω

, the lead is defective. Re-

place the main harness [A] if necessary.

•

Narrow down suspicious parts and close in on the faulty
KIBS part by repeating the continuity tests.
If no abnormality is found in the wiring or connectors, the
KIBS parts are the next likely suspects. Check each part
one by one.
If an abnormality is found, replace the affected KIBS part.

BRAKES 12-41

KIBS (Equipped Models)

Inquiries to Rider

○

Each rider reacts to problems in different ways, so it is important to confirm what kind of condition
the rider is dissatisfied with.

○

Try to find out exactly what problem occurs under exactly what conditions by asking the rider; know-
ing this information may help you reproduce the problem in the shop.

○

The diagnosis sheet will help prevent you from overlooking any keys, so always use it.

Sample Diagnosis Sheet

Rider name:

Registration No. (license plate No.):

Year of initial registration:

Model:

Engine No.:

Frame No.:

Date problem occurred:

Frequency:

Weather:

Mileage:

Phenomenon

□

Brake lever vibration or noise

□

Pedal vibration or noise

□

Indicator light blinks

□

Indicator light remains lit up

□

Braking distance too long

□

Abnormal brake lever movement

□

Abnormal pedal movement

□

KIBS not working

□

KIBS works but indicator light doesn’t light up

□

KIBS operating too frequently

Engine conditions at
problem

□

At start-up

□

After starting

□

At 5 000 r/min (rpm) or more

Road conditions

□

Slippery road

(

□

snow,

□

gravel,

□

other )

□

Rough surface

□

Other

Driving conditions

□

High-speed cornering

□

Driving 10 km/h (6 mph) or above

□

Driving below 10 km/h (6 mph)

□

When stopping

□

When turning

Brake application

□

Gradual

□

Abrupt

Other conditions

□

Large brake lever stroke

□

Large pedal stroke

12-44 BRAKES

KIBS (Equipped Models)

ABS and KIBS Indicator Lights (LED) Inspection

○

In this model, the yellow ABS indicator light (LED) [A] and
yellow warning 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 Electrical System
chapter.

Yellow ABS Indicator Light (LED) and Yellow Warning
Indicator Light (LED) Function

Status

Brake

Condi-

tion

Yellow

ABS

Indicator

Light

(LED)

Yellow

Warning

Indicator

Light

(LED)

Multi-

function

Meter
(LCD)

Normal

KIBS

Goes off

None

Engine

information

communication

error

ABS

Goes off

Goes on

KIBS

Battery voltage

decreases

Low

voltage

ABS*

Blinks

Goes off

None

ABS error

Normal

brake

Goes on

Goes off

None

*: The mode of “Low voltage ABS” controls ABS while

reducing the load to the battery.

NOTE

○

When the yellow ABS indicator light is blinking, the ABS
has been in the low voltage mode (insufficient battery
voltage). When it is in the low voltage mode, the KIBS
system does not function, but the ABS functions. To
recover the KIBS system, charge the battery. (see Re-
freshing Charge in the Electrical System chapter).

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 hy-
draulic 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)

Kawasaki Motorcycle Ninja ZX-6R / Ninja ZX-6R ABS. Service Manual (2013 year) - page 13