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:

Rear Master Cylinder Removal
Unscrew the brake hose banjo bolt [A] and remove the brake hose (see Brake Hose and Pipe Replacement in the Periodic Maintenance chapter). Remove: Rear Master Cylinder Mounting Bolts [B] Foot Guard [C] Screw and Stopper [D] Bolt [E] Front Footpeg Bracket Bolts [F] Cable Guide [G ...

Bolts, Nuts and Fasteners Tightness Inspection
Check the tightness of the bolts and nuts listed here. Also, check to see that each cotter pin is in place and in good condition. NOTE For the engine fasteners, check the tightness of them when the engine is cold (at room temperature). If there are loose fasteners, retighten them to ...

Overview
Kawasaki Intelligent anti-lock Brake System (KIBS) offers enhanced braking stability (ABS performance equivalent to the current model) to supersportmodels, which pitch more than most motorcycles and also offers high-precision front and rear brake pressure control (high-precision ABS) for spo ...