# Front Fork Installation (each Fork Leg) - Kawasaki Ninja ZX-6R Service Manual

Front Fork

## Front Fork Installation (Each Fork Leg)

Install the fork so that the top end [A] of the outer tube as
shown.
7 mm (0.28 in.) [B]
Tighten:
Torque - Lower Front Fork Clamp Bolts: 23 N·m (2.3 kgf·m,
17 ft·lb)
Tighten the two lower front fork clamp bolts alternately
two times to ensure even tightening torque.
Torque - Front Fork Top Plugs: 35 N·m (3.6 kgf·m, 26 ft·lb)
Tighten the front fork top plug [A] before tightening the
handlebar clamp bolt and upper front fork clamp bolt.
The torque of front fork top plug is specified to 35 N·m
(3.6 kgf·m, 26 ft·lb) however, when you use the top
plug wrench (special tool: 57001-1741) [B], reduce the
torque to 90% of the specified value [31 N·m (3.2 kgf·m,
23 ft·lb)] due to the distance [C] between the center of
the square hole, where the torque wrench [D] is fitted,
and that of the octagonal hole of the wrench.
This torque value [31 N·m (3.2 kgf·m, 23 ft·lb)] is ap-
plicable when you use a torque wrench whose length
gives leverage of approximately 310 mm (12.2 in.) be-
tween the grip point to the center of the coupling square.
To obtain the correct tightening torque with your torque
wrench, you need to calculate as follows.
Formula:
a × b ÷ (b + c) = d
[a] Specified torque
[b] Length from center of square hole to grip point
[c] Offset = 44 mm
[d] Tightening torque
For an example:
35 N·m ×310 ÷ (310 + 44) = 31 N·m
Tighten:
Torque - Upper Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m,
15 ft·lb)
Handlebar Clamp Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)
Install the removed parts (see appropriate chapters).
Rebound Damping Force (see Rebound Damping Force
Compression Damping Force (see Compression Damp-
NOTE
NOTE
SUSPENSION 13-11