Kawasaki Ninja Service Manual: Front Fork Oil Change

Kawasaki Ninja Service Manual / Suspension / Front Fork / Front Fork Oil Change

Front Fork Oil Change


Front Fork Oil Change


Front Fork Oil Change


Special Tool - Rod Guide Case Wrench, 35 mm: 57001 -1758

Front Fork Oil Change


NOTICE

A socket of piston rod guide case is shallow (4 mm) and therefore be sure to check that the wrench (Special Tool: 57001-1758) is securely seated on the piston rod guide case.

When loosening the piston rod guide case. If the wrench is not securely seated on it, the piston rod guide case may brake.

Front Fork Oil Change


Pump the inner tube up and down at least ten times to expel the oil from the fork.

Front Fork Oil Change


Front Fork Oil Change


Pour the fork oil until the upper of the inner tube hole [A].

Front Fork Oil Change


Fork Oil Recommended Oil: SHOWA SS-19: 44091-0009 Amount (Per Side): When changing oil: Approx. 420 mL (14.2 US oz.) After disassembly and completely dry (Total): 495 ±2.5 mL (16.7 ±0.085 US oz.)

NOTE

Lifting the outer tube, and insert the piston rod assy.

NOTICE

When inserting, be careful not to damage the piston ring [A].

Front Fork Oil Change


Special Tool - Rod Guide Case Wrench, 35 mm: 57001 -1758

Torque - Piston Rod Guide Case: 90 N·m(9.2 kgf·m, 66 ft·lb)

Front Fork Oil Change


NOTE

Front Fork Oil Change


Formula: a × b ÷ (b + c) = d

[a] Specified torque

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

[c] Offset = 30 mm

[d] Tightening torque

For an example: 90 N·m × 450 ÷ (450 + 30) = 84 N·m

NOTICE

A socket of piston rod guide case is shallow (4 mm) and therefore be sure to check that the wrench (Special Tool: 57001-1758) is securely seated on the piston rod guide case.

When tightening the piston rod guide case. If the wrench is not securely seated on it, the piston rod guide case may brake.

Front Fork Oil Change


Front Fork Oil Change


Front Fork Oil Change


Hold the inner tube vertically in a vise.

Wait until the oil level settles.

With the fork fully compressed, insert a tape measure or rod into the piston rod guide case [A], and measure the distance [B] from the top [C] of the outer tube [D] to the oil.

Fork Oil Level (fully compressed) Standard: 85 ±2 mm (3.35 ±0.08 in.)

Front Fork Oil Change


NOTE

Special Tool - Fork Oil Level Gauge: 57001-1290

Pull the handle slowly to pump out the excess oil until the oil no longer comes out.

If no oil is pumped out, there is insufficient oil in the inner tube. Pour in enough oil, then pump out the excess oil as shown above.

NOTE

After installing the front fork, adjust the spring preload and damping force correctly.

Front Fork Installation (Each Fork Leg)
Install the fork so that the top plug end [A] as shown in the figure. 11 mm (0.43 in.) [B] Steering Stem Head [C] Tighten: Torque - Front Fork Clamp Bolts (Lower): 23 N·m (2.3 kgf·m, ...

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 ...

Other materials:

Cable Removal
Remove: Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Loosen the nuts [A], and slide the lower end of the clutch cable to give the cable plenty of play. Screw in the ...

Loading and accessories information
WARNINGIncorrect loading, improper installation or use of accessories, or modification of your motorcyclemay result in an unsafe riding condition. Before you ride the motorcycle, make sure it is not overloaded and that you have followed these instructions. With the ...

Front Wheel Installation
NOTE The direction of the wheel rotation [A] is shown by an arrow [B] on the wheel spoke. Check the wheel rotation mark on the front wheel and install it. Apply high-temperature grease to the grease seal lips. Fit the collars [A] on the both sides of the hub. The collars are i ...