Kawasaki Ninja Service Manual: Front Fork Disassembly

Kawasaki Ninja Service Manual / Suspension / Front Fork / 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].
Separate the outer tube from the inner tube.

Front Fork Disassembly

Remove the following parts from the inner tube.

Slide Bushing [A] Guide Bushing [B] Washer [C] Oil Seal [D] Retaining Ring [E] Dust Seal [F]

Front Fork Disassembly

Front Fork Oil Change

Remove the front fork (see Front Fork Removal (Each Fork Leg)). Turn the spring preload adjuster fully counterclockwise for removing the piston rod assy easily. Hold the inner tube lower en ...

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] Apply grease ...

Other materials:

Rocker Arm/Tie-Rod Bearing, Sleeve Inspection
NOTICE Do not remove the bearings for inspection. Removal may damage them. Visually inspect the rocker arm, or tie-rod sleeves [A] and needle bearings [B]. The rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the ...

Bolt and Nut Tightening
In accordance with the Periodic Maintenance Chart, it is very important to 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. Please ask your authorized Kawasaki dealer for torque values. 1. Clutch Lever Hol ...

Clutch Cover Assembly
Replace the needle bearings and oil seal with new ones. NOTE Install the needle bearings so that the manufacture’s mark face out. Install the needle bearings [A] and oil seal [B] position as shown in the figure. Press the upper and lower bearings so that the bearing surface [ ...