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:

Oil Pump Removal
Remove: Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Engine Oil (Drain, see Engine Oil Change in the Periodic Maintenance chapter) Sidestand Switch Lead Connector [A] (Disconnect) Bolt [B] and Water Pipe [C] Water Pump Cover Bolts [D] Water Pump Cover [E ...

Subthrottle Valve Actuator Inspection
NOTE Be sure the battery is fully charged. Remove the air cleaner housing (see Air Cleaner Housing Removal in the Fuel System (DFI) chapter). Turn the ignition switch to ON. Check to see that all the subthrottle valves [A] open and close smoothly. Turn the ignition switch to OFF. I ...

Front Fork Removal (Each Fork Leg)
Loosen the front fork top plug [A] beforehand if the fork leg is to be disassembled. Special Tool - Top Plug Wrench (45 mm) [B]: 57001-1741 NOTE Loosen the top plug after loosening the handlebar clamp bolt [C] and upper front fork clamp bolt [D]. Remove: Upper Fairing Assembly (see Up ...