Kawasaki Ninja Service Manual: Front Fork Installation (Each Fork Leg)

Kawasaki Ninja Service Manual / Suspension / Front Fork / Front Fork Installation (Each Fork Leg)

Front Fork Installation (Each Fork Leg)


NOTE

Tighten the two lower front fork clamp bolts alternately two times to ensure even tightening torque.

NOTE

Front Fork Installation (Each Fork Leg)


Formula: a × b ÷ (b + c) = d

[a] Specified torque

[b] Length from center of square hole to grip point

[c] Offset = 44 mm

[d] Tightening torque

Front Fork Installation (Each Fork Leg)


For an example: 35 N·m × 310 ÷ (310 + 44) = 31 N·m

Tighten: Torque - Front Fork Clamp Bolts (Upper): 20 N·m (2.0 kgf·m, 15 ft·lb) Handlebar Clamp Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

Front Fork Removal (Each Fork Leg)
Loosen the front fork top plug [A] beforehand if the fork leg is to be disassembled. Special Tool - Top Plug Wrench (45 mm) [B]: 57001-1741 NOTE Loosen the top plug after loosening the handleb ...

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 ...

Other materials:

Brake Fluid Level Inspection
Check that the brake fluid level in the front brake reservoir [A] is above the lower level line [B]. NOTE Hold the reservoir horizontal by turning the handlebar when checking brake fluid level. If the fluid level is lower than the lower level line, fill the reservoir to the upper lev ...

Valve Installation
NOTICE Do not lap the valve to the valve seat, using the grinding compound. It will come off oxide film treated surface of the valve. Replace the oil seal with a new one. Apply a thin coat of molybdenum disulfide grease to the valve stem before valve installation. Install the springs so ...

Exhaust Pipe Removal
Remove: Radiator (see Radiator and Radiator Fan Removal in the Cooling System chapter) Exhaust Pipe Clamp Bolt [A] (Loosen) Remove the exhaust pipe holder nuts [A], and pull out the exhaust pipe [B] forward from the premuffler chamber. ...