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:

Swingarm Installation
Visually inspect the chain guide [A]. Replace the chain guide if it shows any signs of abnormal wear or damage. Apply a non-permanent locking agent to the threads of the chain guide bolt [B]. Apply plenty of grease to the lip of the oil seals [A]. Be sure to install the oil seals ...

Additional Considerations for High Speed Operation
Brakes: The importance of the brakes, especially during high speed operation, cannot be overemphasized. Check to see that they are correctly adjusted and functioning properly. Steering: Looseness in the steering can cause loss of control. Check to see that the handlebar turns freely but ha ...

Rear Fender Front Installation
Installation is the reverse of removal. Note the following. Run the harness, cables and leads correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). When installing the clamp [A] on the rear fender front [B], install it so that the clamp positions at near the ...