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:

Fuses
Fuses are arranged in the fuse boxes located under the passenger’s seat and in the left fairing. The main fuse is located under the passenger’s seat. If a fuse fails during operation, inspect the electrical system to determine the cause, and then replace it with a new fuse of proper amp ...

Oil Pan Installation
If the oil filter holder bolt [A] was removed, tighten it. Apply a non-permanent locking agent to the threads of the oil filter holder bolt. Torque - Oil Filter Holder Bolt: 35 N·m (3.6 kgf·m, 26 ft·lb) Replace the O-rings [B] with new ones, and apply grease to them. Install the O-ri ...

Subthrottle Sensor Input Voltage Inspection
NOTE Be sure the battery is fully charged. Turn the ignition switch to OFF. Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Disconnect the subthrottle sensor connector and connect the harness adapter [A] between these connectors. Spec ...