Front Forks

1.	Rubber cap	8.	Dust seal
2.	O-ring	9.	Circlip
3.	Cap bolt	10.	Washer
4,	Inner tube	11.	Fork oil seal
5.	Fork spring	12.	Washer
6.	Damper rod	13.	Guide bush
7.	Taper spindle	14.	Outer tube

Front Fork Oil Capacity: 286 ± 4 cm³ (10.1 ±0.14 Imp oz. 9.67±0.14 US oz)

Recommended oil: SAE 5W type SE motor oil

Free Length Limit 517.5mm (20.4 in)

Removal and Disassembly

WARNING: Securely support the motorcycle so there is no danger of it falling over.

Remove:

•   Speedometer cable

•   Front fender

•   Front fork brace

•   Front wheel

•   Headlight unit

Remove:

•   Windscreen assembly

Loosen:

•   Handle crown pinch bolt 1

•   Under bracket pinch bolts 2

Slide down the front fork from the handle crown.

Tighten:

•   Under bracket pinch bolts

Remove:

•   Rubber cap

Loosen:

•   Cap bolt 1

Remove:

•   Disc brake caliper

Loosen:

•   Under bracket pinch bolts

Remove:

•   Front fork

Remove:
• Cap bolt	(inner tube)
• Fork spring	(Inner tube)
• Dust seal	(Outer tube)
• Circlip	(Outer tube)
• Washer	{Outer tube)

Stretch the inner tube, and fill with the fork oil.

Install:

• Cap bolt

Press the inner tube to remove the oil seal from outer tube.

1 Wrap with rag

2 Spacer

3 Turn slowly

CAUTION: If the inner tube is abruptly contracted or air enters the inner tube, the oil may spurt out or the oil seal may spring out. Never touch the inner tube during disassembling operation. Also wrap the oil seal with a rag for safety.

Remove:
• Oil seal	(Outer tube)
• Washer	(Outer tube)
• Cap bolt	(Inner tube)

Drain:

•    Fork oil (into receptacle)

Remove:

•    Damper rod securing bolt

Hold damper rod with Damper Rod Holder (90890-01365)

Remove:

•   Damper rod

•   Damper rod spring

•   Inner fork tube

•   Guide bush   (Outer tube)

Pull 1 inner tube from outer tube.

Inspection

Inspect:

• Inner fork tube

Severely seratched or bent -> Replace.

Damaged oil lock valve ->Replace,

WARNING: Do not attempt to straighten a bent fork tube; this may dangerously weaken tube.

Inspect:

•   Outer fork tube Dents -> Replace

Damaged fork seal seat -> Replace

•   Fork oil seal

Lip damage -> Replace

Outer surface damage -> Replace

Inspect:

• Springs (free length). Out of specification -> Replace

Fork Spring Free Length Limit: 517.5 mm (20.4 in)

Inspect:

• Damper rod

Worn damper rod seal -> Replace

Contamination ->Wash and blow out all passages

Inspect:

• O-ringon cap bolt. Replace if damaged

Assembly

Be sure all components are clean before assembly

1	Damper rod spring
2	Damper rod
3	Inner fork tube
4	Taper spindle
5	Outer fork tube
6	Damper rod securing bolt
7	Guide bush
8	Washer
9	Fork oil sael
10	Circlip
11	Dust seal
12	Fork spring
13	O-ring
14	Cap bolt

Install:

•  Damper rod spring onto Damper rod

•  Damper rod into inner fork tube

Allow rod to slide slowly down tube until it protrudes from bottom.

• Taper spindle onto end of damper rod
• Inner fork tube into outer fork tube

Apply Loctite @ stud N'Bearing Mount (red) to damper rod securing bolt,

Install:

• Damper rod securing bolt through outer fork tube. Hold damper rod with Damper Rod Holder (90890-01365)

Damper Rod Securing Bolt: 23 Nm (2.3m-kg_m 17 ft-lb)

Install:

• Guide bush 1

Press guide bush into the outer fork tube with Fork Seal Driver 2 (90890-01367)

Install:

•   Washer 1

•   Fork oil seal 2

Press fork oil seal into the outer fork tube with Fork Seal Driver 3 (90890-01367)

Install:

•   Washer

•   Circlip

•   Dust seal

Pour specified amount of oil into inner tube

Capacity:

286 ± 4 cm³ (10.1 ± 0.14 Imp oz, 9.67 ±0.14 USoz)

Type:

SAE 10W30 Motor Oil

Install:

• Fork spring

NOTE: When installing the fork spring, the greater pitch (T) should be at the bottom (2).

Install:

•   Cap bolt

•   Front fork  through Under bracket

Tighten:

•   Under bracket pinch bolts

Torque tighten:

Cap Bolt:

23 Nm (2.3 m-kg, 17fMb)

Loosen:

•   Under bracket pinch bolts

Install:

•   Front fork into Handle crown)

NOTE: Be sure the inner fork tube end is flush with the top of the Handle Crown.

Torque tighten:

Handle crown pinch bolt: 20 Nm (2.0 m-kg, 14 ft-lb)

Under bracket pinch bolt: 23 Nm (2.3 m-kg, 17 ft-lb)

Continue assembly in reverse of Removal and Disassembly order.

Install and Torque tighten each component as follows:

Disc Brake Caliper:

35 Nm (3.5 m-kg, 25 ft-lb) Front wheel axle nut:

78 Nm (7.8 m-kg, 50 ft-lb) Wheel axle pinch bolt:

23 Nm (2.3 m-kg, 17 ft-lb)