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:

Engine Stop Switch Operation Inspection
First Step Set the gear position in the neutral position. Turn the ignition switch to ON. Turn the engine stop switch to stop position [A]. Push the starter button. The engine does not start. If the engine starts, inspect the engine stop switch (see Switch Inspection in the Electri ...

KIBS Hydraulic Unit Inspection
Remove the KIBS hydraulic unit (see KIBS Hydraulic Unit Removal). Visually inspect the connector terminals [A]. Replace the KIBS hydraulic unit or main harness if either of the terminals are cracked, bent, or otherwise damaged. If the KIBS hydraulic unit connector is clogged with mud or ...

Throttle Grip and Cables
Free Play Inspection Refer to the Throttle Control System Inspection in the Periodic Maintenance chapter. Free Play Adjustment Refer to the Throttle Control System Inspection in the Periodic Maintenance chapter. Cable Installation Install the throttle cables in accordance with the Cable, ...