Kawasaki Ninja Service Manual: Front Fork Disassembly

Kawasaki Ninja Service Manual / Suspension / Front Fork / 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].
Separate the outer tube from the inner tube.

Front Fork Disassembly

Remove the following parts from the inner tube.

Slide Bushing [A] Guide Bushing [B] Washer [C] Oil Seal [D] Retaining Ring [E] Dust Seal [F]

Front Fork Disassembly

Front Fork Oil Change

Remove the front fork (see Front Fork Removal (Each Fork Leg)). Turn the spring preload adjuster fully counterclockwise for removing the piston rod assy easily. Hold the inner tube lower en ...

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] Apply grease ...

Other materials:

Shift Pedal Removal
Remove: Shift Lever Bolt [A] Front Footpeg Bracket Bolts [B] If the tie-rod [C] is to be removed from the shift pedal and the shift lever, loosen the tie-rod locknuts [D]. The front tie-rod locknut is left-hand thread. Remove: Shift Pedal Mounting Bolt [A] ...

Rider’s Seat Installation
Insert the tabs on the front of the rider’s seat into the slots in the frame and secure the seat with mounting bolts. Install the seat cover and bolts. A. Rider’s Seat B. Tabs C. Slots D. Stays ...

Battery Installation
Visually inspect the surface of the battery container. If any signs of cracking or electrolyte leakage from the sides of the battery. Put the battery into the rear fender Install the band [A]. Connect the positive (+) cable [B] (red cap) to the positive (+) terminal first, and then ...