Kawasaki Ninja Service Manual: Front Fork Assembly

Kawasaki Ninja Service Manual / Suspension / Front Fork / Front Fork Assembly

Replace the following parts with new ones.

Slide Bushing

Guide Bushing

Oil Seal

Install the following parts to the inner tube [A].

Dust Seal [B] Retaining Ring [C]

Front Fork Assembly

Apply grease to the oil seal lips.
Install the oil seal [A] so that the stamp side faces lower side.
Install the washer [B] so that the chamfer side faces upper side.
Install the guide bushing [C] so that the slit of it is positioned perpendicular to the traveling direction.

Install the slide bushing [D] so that the slit of it is positioned perpendicular to the traveling direction.

Apply grease to the slide and guide bushings and oil seal.

Front Fork Assembly

Insert the inner tube to the outer tube.
After installing the washer, install the oil seal [A] by using the fork oil seal driver [B].

Special Tool - Fork Oil Seal Driver, 43: 57001-1530
Install the retaining ring and dust seal.
Pour in the specified type of oil (see Front Fork Oil Change).

Front Fork Assembly

Front Fork Disassembly

Remove the front fork (see Front Fork Removal (Each Fork Leg)) Drain the fork oil (see Front Fork Oil Change). Take the dust seal [A] off the outer tube. Remove the retaining ring [B]. Se ...

Inner Tube Inspection

Visually inspect the inner tube [A]. If there is any damage, replace the inner tube. Since damage to the inner tube damages the oil seal, replace the oil seal whenever the inner tube is replac ...

Other materials:

Water Pump Impeller Disassembly/Assembly
Remove the water pump impeller (see Oil Pump Removal in the Engine Lubrication System chapter). The sealing seat and rubber seal may be removed easily by hand. Apply coolant around the surfaces of the rubber seal and sealing seat. Install the rubber seal [A] and sealing seat [B] into ...

ESD Actuator Input Voltage Inspection
NOTE Be sure the battery is fully charged. Turn the ignition switch to OFF. Disconnect the ESD actuator connector and connect a suitable measuring leads [A] between these connectors as shown. Main Harness [B] ESD Actuator [C] Connect the peak voltage adapter [D] and a digital ...

Exploded View
EO: Apply engine oil. G: Apply grease. L: Apply a non-permanent locking agent. M: Apply molybdenum disulfide grease. MO: Apply molybdenum disulfide oil solution. (mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1) R: Replacement Parts S: Follow the s ...