Kawasaki Ninja Service Manual: Front Fork Assembly

Kawasaki Ninja Service Manual / Suspension / Front Fork / Front Fork Assembly

Replace the following parts with new ones.

Slide Bushing

Guide Bushing

Oil Seal

Install the following parts to the inner tube [A].

Dust Seal [B] Retaining Ring [C]

Front Fork Assembly

Apply grease to the oil seal lips.
Install the oil seal [A] so that the stamp side faces lower side.
Install the washer [B] so that the chamfer side faces upper side.
Install the guide bushing [C] so that the slit of it is positioned perpendicular to the traveling direction.

Install the slide bushing [D] so that the slit of it is positioned perpendicular to the traveling direction.

Apply grease to the slide and guide bushings and oil seal.

Front Fork Assembly

Insert the inner tube to the outer tube.
After installing the washer, install the oil seal [A] by using the fork oil seal driver [B].

Special Tool - Fork Oil Seal Driver, 43: 57001-1530
Install the retaining ring and dust seal.
Pour in the specified type of oil (see Front Fork Oil Change).

Front Fork Assembly

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 ...

Inner Tube Inspection

Visually inspect the inner tube [A]. If there is any damage, replace the inner tube. Since damage to the inner tube damages the oil seal, replace the oil seal whenever the inner tube is replac ...

Other materials:

Fuel Flow Rate Inspection
WARNINGGasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light. Do not smoke. T ...

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 handlebar clamp bolt [C] and upper front fork clamp bolt [D]. Remove: Upper Fairing Assembly (see Up ...

Lights and Switches Operation Inspection
First Step Set the gear position in the neutral position. Turn the ignition switch to ON. The following lights should go on according to below table. If the following light does not go on, inspect the meter unit (see Meter Unit Inspection in the Electrical System chapter). ...