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:

Subthrottle Valve Actuator Input Voltage Inspection
NOTE Be sure the battery is fully charged. Turn the ignition switch to OFF. Disconnect the subthrottle valve actuator connector and connect the measuring adapter [A] between these connectors as shown in the figure. Main Harness [B] Subthrottle Valve Actuator [C] Special Tool ...

Fuel Tank Installation
Note the above WARNING (see Fuel Tank Removal). Run the hoses correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter). Check that the dampers [A] are in place on the fuel tank. If the dampers are damaged or deteriorated, replace them. If the fuel tank brack ...

Cylinder Head Warp Inspection
Clean the cylinder head. Lay a straightedge across the lower surface of the cylinder head at several positions. Use a thickness gauge [A] to measure the space between the straightedge [B] and the head. Cylinder Head Warp Standard: – – – Service Limit: 0.05 mm (0.0020 in.) ...