Kawasaki Ninja Service Manual: Front Fork Installation (Each Fork Leg)

• Install the fork so that the top plug end [A] as shown in the figure.

  11 mm (0.43 in.) [B] Steering Stem Head [C]

• Tighten: Torque - Front Fork Clamp Bolts (Lower): 23 N·m (2.3 kgf·m, 17 ft·lb)

NOTE

Tighten the two lower front fork clamp bolts alternately two times to ensure even tightening torque.

NOTE

• Tighten the front fork top plug [A] before tightening the handlebar clamp bolt and upper front fork clamp bolt
• The torque of front fork top plug is specified to 35 N·m (3.6 kgf·m, 26 ft·lb) however, when you use the top plug wrench (special tool: 57001-1741) [B], reduce the torque to 90% of the specified value [31 N·m (3.2 kgf·m, 23 ft·lb)] due to the distance [C] between the center of the square hole, where the torque wrench [D] is fitted, and that of the octagonal hole of the wrench.
• This torque value [31 N·m (3.2 kgf·m, 23 ft·lb)] is applicable when you use a torque wrench whose length gives leverage of approximately 310 mm (12.2 in.) between the grip point to the center of the coupling square.
• To obtain the correct tightening torque with your torque wrench, you need to calculate as follows.

Formula: a × b ÷ (b + c) = d

[a] Specified torque

[b] Length from center of square hole to grip point

[c] Offset = 44 mm

[d] Tightening torque

For an example: 35 N·m × 310 ÷ (310 + 44) = 31 N·m

Tighten: Torque - Front Fork Clamp Bolts (Upper): 20 N·m (2.0 kgf·m, 15 ft·lb) Handlebar Clamp Bolts: 25 N·m (2.5 kgf·m, 18 ft·lb)

• Install the removed parts (see appropriate chapters).
• Adjust: Spring Preload (see Spring Preload Adjustment) Rebound Damping Force (see Rebound Damping Force Adjustment) Compression Damping Force (see Compression Damping Force Adjustment)