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:

Intake Air Pressure Sensor #2 Removal
NOTICE Never drop the intake air pressure sensor #2 especially on a hard surface. Such a shock to the sensor can damage it. Remove: Air Cleaner Housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter) Intake Air Pressure Sensor #2 Connector [A] Remove the intake air ...

Front Wheel Rotation Sensor Removal
NOTICE The wheel rotation sensor should be handled carefully, never struck sharply, as with a hammer, or allowed to fall on a hard surface since the wheel rotation sensor is precision made. Be careful not to get water or mud on the wheel rotation sensor. Do not try to disassemble or repair t ...

Turn Signal Relay Inspection
Remove the battery (see Battery Removal). Take the turn signal relay [A] off the rear fender. Disconnect the connector [B]. Connect one 12 V battery and turn signal lights as indicated in the figure, and count how many times the lights blink for one minute. Turn Signal Relay ...