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

Kawasaki Ninja Service Manual / Suspension / Front Fork / 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

Front Fork Removal (Each Fork Leg)

NOTE

Loosen the top plug after loosening the handlebar clamp bolt [C] and upper front fork clamp bolt [D].

Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Fender (see Front Fender Removal in the Frame chapter)
Loosen: Handlebar Clamp Bolt [A] Upper Front Fork Clamp Bolt [B] Lower Front Fork Clamp Bolts [C]
With a twisting motion, work the fork leg down and out.

Front Fork Removal (Each Fork Leg)

Spring Preload Adjustment

To adjust the spring preload, turn the spring preload adjuster [A]. The standard adjuster setting is the 6 turns in from the fully counterclockwise position. WARNINGIf both adjusters ...

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, ...

Other materials:

Rear Wheel Rotation Sensor Signal Abnormal (Service Code b 44)
Measure the air gap between the rear wheel rotation sensor and sensor rotor. Thickness Gauge [A] Air Gap Standard: 0.4 1.6 mm (0.02 0.06 in.) If the measurement is not the standard, check each part for deformation and looseness and correct accordingly. If the measurement is the sta ...

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: ...

Pressure Testing
Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Radiator Cap [A] Remove the radiator cap in two steps. First turn the cap counterclockwise to the first stop. Then push and turn it further in the same direction and remove the cap. Install the ...