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:

CAN Communication Line
CAN Communication Line Resistance Inspection In this model, resistors for CAN communication line are built in the ECU [A] and meter unit. Refer to the Meter Unit Inspection in the Electrical System chapter for the resistor in the meter unit. Turn the ignition switch to OFF. Remove: EC ...

External Shift Mechanism Inspection
Examine the shift shaft [A] for any damage. If the shaft is bent, straighten or replace it. If the serration [B] are damaged, replace the shaft. If the spring [C] is damaged in any way, replace it. If the shift mechanism arm [D] is damaged in any way, replace the shaft. Check the s ...

Wheel Rotation Sensor Air Gap Inspection
Raise the front/rear wheel off the ground (see Front/Rear Wheel Removal in the Wheels/Tires chapter). Measure the air gap between the sensor and sensor rotor at several points by turning the wheel slowly. Thickness Gauge [A] Wheel Rotation Sensor Air Gap Standard: Front 0.4 1.6 mm ...