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:

Camshaft Installation
NOTE The exhaust camshaft has a 1001 EX mark [A] and the intake camshaft has a 3154 IN mark [B]. Be careful not to mix up these shafts. Install the camshaft sprockets as shown in the figure. #4 Cam Positions [A] Intake Camshaft Sprocket [B] Exhaust Camshaft Sprocket [C] The int ...

Keys
This motorcycle has a combination key, which is used for the ignition switch, steering lock, seat lock, and fuel tank cap. Included with the key is a key number, which may be stamped on a separate plate. Record the key number in the space provided and store the number in a safe place. If y ...

Front Forks/Rear Shock Absorber Operation Inspection
Pump the forks down and up [A] 4 or 5 times, and inspect the smooth stroke. If the forks do not smoothly or noise is found, inspect the fork oil level or fork clamps (see Front Fork Oil Change in the Suspension chapter). Pump the rear seat down and up [A] 4 or 5 times, and inspec ...