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:

Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection
NOTE Before this inspection, confirm the pulley is original position (see Exhaust Butterfly Valve Actuator Installation). Disconnect: 3 Pins Connector [A] (see Exhaust Butterfly Valve Actuator Sensor Output Voltage Inspection) 2 Pins Connector [B] Connect the harness adapter [A ...

Coolant Level Inspection
Situate the motorcycle so that it is perpendicular to the ground. Check the coolant level through the coolant level gauge on the reserve tank located to the left of the engine. The coolant level should be between the “F” (Full) and “L” (Low) level lines. A. Reserve Ta ...

Lower Crankcase Assembly
Install the ball bearing [A] and the oil level inspection window [B] until they are bottomed Apply soap and water solution to the oil level inspection window before installation. Install the new circlip [C]. Apply a non-permanent locking agent to the oil passage plug [D]. Tighten: ...