Kawasaki Ninja Service Manual: Front Fork Assembly

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

Slide Bushing

Guide Bushing

Oil Seal

Dust Seal [B] Retaining Ring [C]

Front Fork Assembly


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


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:

Piston Ring Thickness Inspection
Measure the piston ring thickness. Use the micrometer to measure at several points around the ring. Piston Ring Thickness Standard: Top [A] 0.77 0.79 mm (0.0303 0.0311 in.) Second [B] 0.78 0.79 mm (0.0307 0.0311 in.) Service Limit: Top 0.70 mm (0.0276 in.) Second 0.71 mm (0.0280 ...

Check 3-7 Stop Watch Inspection
Connect the leads in the same circuit as Check 3-2. By pushing the upper button each time to set the stop watch mode. Connect the insulated auxiliary lead processed insulation to the terminal [13] as shown in the figure, then stop watch start to count. While count the stop watch, conn ...

Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection
Remove the connecting rod big end (see Connecting Rod Removal). Cut strips of plastigage to crankpin width. Place a strip on the crankpin parallel to the crankshaft installed in the correct position. Tighten the connecting rod big end nuts to the specified torque (see Connecting Rod I ...