SUSPENSION 13-9

Front Fork

•Hold the outer tube vertically in a vise and compress the

•fork completely.

•Wait until the oil level stabilizes.

Use the fork oil level gauge [A] to measure the distance between the top of the inner tube to the oil level.

Special Tool - Fork Oil Level Gauge: 57001–1290

○Set the oil level gauge stopper [B] so that the distance [C] from the bottom of the stopper to the lower end of the pipe is the standard oil level distance.

○A correct measurement can not be obtained unless the level gauge pipe is placed in the center of the inner tube.

Oil Level (fully compressed, without spring)

Standard: 115 ±2 mm (4.53 ±0.08 in.)

○Place the stopper of the level gauge at the top [E] of the inner tube [D] and pull the handle slowly to draw out the excess oil from fork into the gauge, thus attaining the standard level.

○If not oil is drawn out, there is not enough oil in the fork. Pour in some more oil and measure again.

•Repeat the same procedure for adjusting the other fork.

•Install the fork spring [A], fork spring seat [B] and collar

•[C].

•Inspect the top plug O-ring and replace it with a new one. Install the front fork (see Front Fork Installation).

Front• Fork Disassembly

•Remove the front fork (see Front Fork Removal). Remove the top plug [A] with O-ring, take out the collar

•[B], spring seat [C], and spring [D]. Drain the fork oil (see Fork Oil Change).

•Remove the Allen bolt [C] from the bottom of the fork.

Special Tools - Fork Cylinder Holder Handle: 57001-183 [D]

Fork Cylinder Holder Adapter: 57001-1057

[E]

NOTE

○Hold the outer tube in a vise [A], stop the cylinder unit [B] from turning by using the special tools, and unscrew the Allen bolt.

13-10 SUSPENSION

Front Fork

•Remove the cylinder unit [A], washer, and the spring [B] from the inner tube.

•Remove the following from the top of the outer tube: Dust Seal [A]

Retaining Ring [B]

•Separate the inner tube [A] from the outer tube [B].

NOTE

○From the compressed state, firmly pull down the outer tube a few times towards the direction of elongation.

•Remove the following from the inner tube: Guide Bushing (inner) [A]

Guide Bushing (outer) [B] Washer [C]

Oil Seal [D]

•Removetube. the cylinder base [A] from the bottom of the outer

SUSPENSION 13-11

Front Fork

Front• Fork Assembly

•Check the top plug O-ring and replace it with a new one. Replace the following parts with new ones:

Retaining Ring [A]

Dust Seal [B]

Oil Seal [C]

Inner Guide Bushing [D]

Outer Guide Bushing [E]

Fork Bottom Allen Bolt Gasket [F]

•Install the guide bushing on the end of the inner tube.

•Insert the cylinder unit and the spring into the inner tube, and install the cylinder base [B] onto the cylinder end [A] that protrudes from the bottom.

○•Install the cylinder base starting with its stepped end. Insert the inner tube, cylinder unit, washer, spring, and cylinder base as a set into the outer tube.

•Install the guide bushing into the outer tube.

•After installing the washer, install the oil seal [A] by using the fork oil seal driver [B].

Special Tool - Fork Oil Seal Driver: 57001-1288

○•Apply high-temperature grease to the oil seal lips.

•Install the retaining ring into the outer tube. Install the dust seal by hand.

•Apply non-permanent locking agent to the threads of the

•bottom Allen bolt [C].

•Hold the front fork horizontally in a vise [A].

Hold the cylinder unit [B] with the special tools and tighten the bottom Allen bolt to secure the cylinder in place.

Torque - Front Fork Bottom Allen Bolt: 30 N·m (3.1 kgf·m, 22 ft·lb)

Special Tools - Fork Cylinder Holder Handle: 57001-183 [D] Fork Cylinder Holder Adapter: 57001-1057

• [E]

Pour in the specified type of oil (see Front Fork Oil Change).

13-12 SUSPENSION

Front Fork

Inner• Tube/Outer Tube Inspection

Visually inspect the inner tube [A] and repair any nicks or rust by using an oil stone.

If the damage is not repairable, replace the inner tube. Since damage to the inner tube damages the oil seal slip, replace the oil seal whenever the inner tube is repaired or replaced.

CAUTION

If the inner tube is badly nicked or bent, replace it. Excessive bending, followed by subsequent straightening, can weaken the inner tube.

•Place the inner tube in the outer tube [B] and pump them back and forth manually to check for smooth operation. If the movement is not smooth, replace both the inner tube and the outer tube.

WARNING

Replace the inner and outer tubes with new ones if they are bent because it is dangerous to use them by repairing them.

Make sure to inspect the inner and outer tubes of the other side.

Dust• Seal Inspection

Inspect the dust seal [A] for any signs of deterioration or damage.

Replace it if necessary.

Fork• Spring Inspection

Measure the free length [B] of the fork spring [A].

If the measured length is shorter than the service limit, the spring must be replaced. If the free length of the replacement spring and that of the remaining spring vary greatly, the remaining spring should also be replaced in order to keep the fork legs balanced to ensure stability.

Fork Spring Free Length

Standard: 277.2 mm (10.91 in.)

Service Limit: 272 mm (10.71 in.)