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

Kawasaki Ninja Service Manual / Suspension / Front Fork / 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

Front Fork Removal (Each Fork Leg)

NOTE

Loosen the top plug after loosening the handlebar clamp bolt [C] and upper front fork clamp bolt [D].

Remove: Upper Fairing Assembly (see Upper Fairing Assembly Removal in the Frame chapter) Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter) Front Fender (see Front Fender Removal in the Frame chapter)
Loosen: Handlebar Clamp Bolt [A] Upper Front Fork Clamp Bolt [B] Lower Front Fork Clamp Bolts [C]
With a twisting motion, work the fork leg down and out.

Front Fork Removal (Each Fork Leg)

Spring Preload Adjustment

To adjust the spring preload, turn the spring preload adjuster [A]. The standard adjuster setting is the 6 turns in from the fully counterclockwise position. WARNINGIf both adjusters ...

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, ...

Other materials:

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 ...

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 ...

Rear Shock Absorber Scrapping
WARNINGPressurized nitrogen may explode when heated. The rear shock contains nitrogen gas. To avoid an explosion, do not incinerate the shock body without first releasing the nitrogen and removing the shraeder valve. Remove the rear shock absorber (see Rear Shock Ab ...