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:

Shift Drum Assembly
Press and insert the ball bearing [A] on the shift drum [B] until it is bottomed. Install: Ball Bearing [C] Dowel Pin [D] and Shift Drum Cam [E] Align the pin with the groove in the shift drum cam. Apply a non-permanent locking agent to the shift drum cam holder bolt [F]. Tight ...

Sidestand Removal
Raise the rear wheel off the ground with the stand [A]. Remove: Sidestand Switch Bolt [A] Sidestand Switch [B] Remove: Spring [A] Sidestand Nut [B] Sidestand Bolt [C] Sidestand [D] ...

Engine Sprocket Removal
Remove: Engine Sprocket Cover Bolts [A] Engine Sprocket Cover [B] Flatten out the bended washer [A]. Remove the engine sprocket nut [B] and washer. NOTE When loosening the engine sprocket nut, hold the rear brake on. Raise the rear wheel off the ground with the stand. ...