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:

Front Footpeg Position
The right and left front footpegs can be selected to one of two positions to suit the front preferences. Have the front footpeg positions changed by an authorized Kawasaki dealer. A. Bolts B. Upper Position (Standard) C. Lower Position NOTE Install the front footpegs with same heig ...

Connecting Rod Big End Side Clearance Inspection
Measure connecting rod big end side clearance. Insert a thickness gauge [A] between the big end and either crank web to determine clearance. Connecting Rod Big End Side Clearance Standard: 0.13 0.38 mm (0.0051 0.0150 in.) Service Limit: 0.58 mm (0.023 in.) If the clearance exceeds ...

Idle Speed Control Valve Actuator Installation
Replace the O-ring [A] with a new one. Apply engine oil to the new O-ring. Install the idle speed control valve [A] as shown in the figure. 10° [B] Tighten: Torque - Idle Speed Control Valve Actuator Retainer Screws: 2.06 N·m (0.21 kgf·m, 18 in·lb) Install th ...