Category Archives: ANUAL SERVICE M

FORK DAMPER INSTALLATION

’05-’07 shown: FORK DAMPER ASSEMBLY

FORK DAMPER INSTALLATION

Wipe the oil completely off the fork spring.

Install the fork spring into the fork assembly. Temporarily install the fork damper assembly into the fork assembly.

FORK DAMPER INSTALLATION

Measure the combined length of the lock nut and piston rod end again.

STANDARD: 11 — 13 mm (0.43 — 0.51 in)

Install the push rod into the piston rod until it stops.

Apply fork oil to new O-ring and install it.

Install the fork center bolt to the fork damper piston rod by aligning the flat-side of the center bolt adjusting rod with the flat-side of the push rod. Tighten the center bolt fully by hand.

Set the axle holder of the slider in a vise with a piece of wood or soft jaws to avoid damage.

Push the fork damper out of the lock nut from slider, while install the piston base or mechanic’s stopper tool between the axle holder and lock nut.

TOOL:

Piston base 07958-2500001 or

Fork rod stopper 07AMB-KZ3A100

(U. S.A. only)

Measure the length of the lock nut and center bolt clearance.

STANDARD: 1.5 — 2.0 mm (0.06 — 0.08 in)

If the clearance is out of specification, check the lock nut and center bolt installation.

Tighten the lock nut to the center bolt by hand until they touch.

Tighten the lock nut to the specified torque. TORQUE: 22 N m (2.2 kgf m, 16 Ibf ft)

Do not over-tighten the vise on the axle holder.

LOCK NUT

PISTON BASE

CENTER BOLT

flfYr

FORK DAMPER INSTALLATION

ЦШI

O-RING

Check the push rod installation by turning the push rod right and left.

FORK DAMPER INSTALLATION

FORK DAMPER INSTALLATION

LOCK NUT

CENTER BOLT

Be careful not to damage the lock nut and fork center bolt hole.

AXLE HOLDER

FORK DAMPER INSTALLATIONRemove the piston base or mechanic’s stopper tool between the axle holder and lock nut while pushing the fork damper.

LOCK NUT

PISTON BASE

CENTER BOLT

Install the fork center bolt into the axle holder and tighten it to the specified torque.

TORQUE: 69 Nm (7.0 kgf m, 51 Ibf ft)

FORK DAMPER INSTALLATION

Measure the length between the axle holder and outer tube.

Compare the length at assembly and disassembly; they should be same length.

STANDARD: 317 ± 2 mm (12.5 ± 0.08 in)

If the length at assembly is longer than at disassem­bly, check the center bolt and lock nut installation.

OIL CAPACITY ADJUSTMENT

FORK DAMPER INSTALLATION

Remove the fork damper assembly from the outer tube.

Be sure the oil capacity is the same in both fork legs.

Pour the recommended fork oil into the fork leg.

RECOMMENDED OIL:

Pro Honda HP Fork Oil 5W or equivalent

STANDARD OIL CAPACITY:

FORK DAMPER INSTALLATION

05 — ’07: 332 cm1 (11.2 oz, 11.7 Imp oz) After ’07: 324 cm3 (11.0 US oz, 11.4 Imp oz)

Maximum oil capacity

402 cm3 (13.6 US oz, 14.2 Imp oz)

Slightly stiffer near full compression.

Minimum oil capacity

306 cm3 (10.3 US oz, 10.8 Imp oz)

Slightly softer near full compression.

damper assembly into the outer tube.

FORK DAMPER INSTALLATION

BOTTOM BRIDGE PINCH BOLTS

LOCK NUT WRENCH

FORK DAMPER INSTALLATION

Refer to torque wrench reading information, on Ipage 14-5) service information.

07WMA-KZ30100

INSTALLATION

Install the fork leg and tighten the fork bottom bridge pinch bolts to the specified torque.

TORQUE: 20 N m (2.0 kgf m, 15 Ibf ft)

Tighten the fork damper to the specified torque using the special tool.

TORQUE: Actual: 34 N m (3.5 kgf m, 25 Ibf-ft)

Indicated: 31 N-m (3.2 kgf m, 23 Ibf-ft)

TOOL:

Lock nut wrench, 50 mm

FORK DAMPER INSTALLATIONSTANDARD POSITION

FORK DAMPER INSTALLATION

PRESSURE RELEASE SCREW

Loosen the bottom bridge pinch bolts.

For ease when releasing the air pressure after the forks are installed, position the fork outer tubes so the pressure release screws are in front of the com­pression adjusters.

BOTTOM BRIDGE PINCH BOLTS

Align the top surface of the top bridge with the outer tube upper surface as shown.

Tighten the fork bottom bridge pinch bolts to the specified torque.

TORQUE: 20 N m (2.0 kgf m, 15 Ibf ft)

Tighten the fork top bridge pinch bolts to the speci­fied torque.

TORQUE: 22 N m (2.2 kgf m, 16 Ibf ft)

NOTICE

FORK DAMPER INSTALLATION

TOP BRIDGE PINCH BOLTS

Over-tightening the pinch bolts can deform the outer tube. A deformed outer tube must be replaced.

Inspect the wear rings for wear or damage. Replace the wear ring, if it is 1.5 mm (0.06 ii with the outer tube.

WEAR RINGS

FORK DAMPER INSTALLATION

Make sure the wear rings with their end gaps facing rearward.

Clean and apply locking agent to the fork protector mounting bolt threads.

SCREWS/CLAMP

FORK PROTECTOR

BOLTS/ CLAMP I

CALIPER *

MOUNTING

BOLTS

FORK DAMPER INSTALLATION

Install the fork protector and tighten the mounting bolts to the specified torque.

TORQUE: 7 N m (0.7 kgf m, 5.2 lbf-ft)

Clean and apply locking agent to the front brake cal­iper mounting bolt threads.

Install the front brake caliper and tighten the mount­ing bolts to the specified torque.

TORQUE: 30 Nm (3.1 kgf m, 22 Ibf ft)

BOLTS

Install the tripmeter cable clamp and screws. Tighten the tripmeter cable clamp screws to the specified torque.

TORQUE: 0.7 N-m (0.1 kgf m, 0.5 Ibf ft)

Install the brake hose clamp and bolts.

COMPRESSION ADJUSTER

REBOUND ADJUSTER

FORK DAMPER INSTALLATION

Return the rebound adjuster and compression adjuster to the original positions as noted during removal.

After‘07: Install the steering damper (page 14-38) if it was removed.

Install the following:

— Front visor (’05 — ’07: page 3-5, After ’07: page 3­6)

— Front wheel (page 14-12)

INSPECTION

FORK CAP

SPRING

-RINGS

INSPECTION

BUSHING

Check the fork cap assembly for damage.

Check the bushing for excessive wear or scratches. Check the spring for fatigue or damage.

Check the compression adjuster for clicks.

Replace the fork cap as an assembly if necessary.

INSPECTION

dГЯ

Apply fork oil to new O-rings and install them.

FORK CENTER BOLT

ADJUSTER ROD

CENTER BOLT

Check the fork center bolt for damage.

INSPECTION

Check the adjuster rod for stepped wear or damage. Check the rebound adjuster for clicks.

Replace the fork center bolt as an assembly if neces­sary.

Apply fork oil to a new O-ring and install it.

SLIDER/OUTER TUBE

INSPECTION

Check the outer tube and slider for score marks, scratches and excessive or abnormal wear.

Check the outer tube for damage or bend.

Set the slider on V-blocks and measure the runout.

Turn the slider and measure the runout using a dial 05 ~ shown indicator.

INSPECTION

SLIDER

Actual runout is 1/2 of the total indicator reading.

SERVICE LIMIT: 0.20 mm (0.008 in)

Do not reuse the slider if it is bent.

Replace if the service limit is exceeded, or there are scratches or nicks that will allow fork oil to leak past the seals.

FORK SPRING

Measure the fork spring free length by placing it on a flat surface.

SERVICE LIMIT: 493 mm (19.4 in)

BUSHING/BACK-UP RING

BUSHING

INSPECTION

Check the bushing for excessive wear or scratches. If copper appears on the surface, replace the bush­ing.

Replace the back-up ring if there is distortion at the points shown.

Remove any metal powder from the slider and guide bushings with a nylon brush and fork oil.

BACK-UP RING

FORK DAMPER

PISTON ROD

’05 — ’07 shown:

FORK DAMPER

INSPECTION

Check the fork damper for bends or damage.

Check the fork damper piston rod for bends, wear or damage.

Check the fork damper operation by pumping the piston rod.

If the operation is not smooth, fill the fork damper with fork oil and check the fork damper operation again (page 14-25).

ASSEMBLY

05 — ’07 shown

INSPECTIONSLIDER BUSHING

SLIDER

PLUG BOLT

OUTER TUBE

FORK CAP

GUIDE BUSHING

•a O-RINGS

FORK DAMPER

PUSH ROD

O-RING

CENTER BOLT

/ DUST SEAL / 7

ф у/ j j / j J *ШШ BACK-UP RING

FORK SPRING WEAR STOPPER RING

Before assembly, wash all parts with a high flash­point or non-flammable solvent and wipe them dry.

OUTER TUBE AND SLIDER ASSEMBLY

Wrap the end of the slider with tape. m ічт тдрс

Coat new oil seal and dust seal lips with fork oil. / / "

Install the dust seal and stopper ring onto the slider.

Install the oil seal onto the slider with its marked

side facing the dust seal. 1

Remove the tape from the end of the slider.

STOPPER RING

GUIDE BUSHING

INSPECTION

Be careful not to damage the slider bushing coating. Do not open the slider bushing more than necessary.

Install the back-up ring, guide bushing and slider bushing.

NOTE:

SLIDER BUSHING BACK-UP RING

Remove the burrs from the bushing mating surface, being careful not to peel off the coating.

Coat the slider and guide bushings with fork oil and install the slider into the outer tube.

’05 — ’07 shown:

07VMD-KZ30100 or 07VMD-KZ3010A (U. S.A. only)

SLIDER

DUST SEAL

INSPECTION

Drive in the guide bushing together with the back­up ring into the outer tube using the special tool. Drive the oil seal into the outer tube using the spe­cial tool.

TOOL:

Install the stopper ring into the groove in the outer tube.

Install the dust seal.

FORK DAMPER FORK CAP ASSEMBLY

INSPECTION

THREADS

FORK DAMPER REFILLING/ASSEMBLY

Clean the fork cap assembly and fork damper threads.

Fork seal driver, 47 mm

Extend the fork damper piston rod to its maximum length.

FORK DAMPER

INSPECTION

Pour the recommended fork oil into the fork damper.

RECOMMENDED FORK OIL:

Pro Honda HP Fork Oil 5W or equivalent

STANDARD CAPACITY:

192 cm3 (6.5 US oz, 6.8 Imp oz)

INSPECTION

INSPECTION

INSPECTION

Be careful not to damage the fork cap bushing.

Apply fork oil to the bushing and new О-rings on the

O-RINGS

FORK DAMPER

INSPECTION

fork cap assembly. 4га

Extend the fork damper piston rod to maximum.

Hold the rod end, install the fork cap assembly into the fork damper.

If it is difficult to install the fork cap assembly, the fork damper oil level might be higher than standard.

Inspect the fork damper oil level again.

Set the fork damper in a vise with a piece of wood or soft jaws to avoid damage.

Do nor over-hghten the vise.

FORK DAMPER FORK CAP ASSEMBLY

INSPECTION

Tighten the fork cap assembly to the specified torque by holding the fork damper using the special tool.

TOOL:

Lock nut wrench, 50 mm 07WMA-KZ30100

TORQUE: 30 N m (3.1 kgf-m, 22 Ibf ft)

INSPECTION

Hold the fork damper in an upright position and pump the fork piston rod 100 mm (3.9 in) slowly, several times.

Turn the lock nut clockwise until it is lightly seated.

NOTE:

INSPECTION

• Set the rebound adjuster and compression adjuster counterclockwise to the softest position.

• Check the fork damper piston rod sliding surface for damage.

• Apply fork oil to the fork damper piston rod slid­ing surface.

Be careful not to bend or damage the fork damper piston rod when the piston rod is stroked.

Cover the piston rod end with a clean shop towel to prevent damage.

Blow out any extra oil in the fork damper spring chamber by fully stroking the fork damper piston rod.

Drain the extra oil from the oil hole (After ’07: oil,

By doing this procedure, about 17 cm3 of fork fluid will be drained from the damper spring chamber through the oil hole IAfter ’07: oil holes). This will cause 7 75 cm3 of fork fluid to be left in the chamber.

INSPECTION

’05 — ’07 shown:

holes) of the fork damper. 05 ~ 07 shown: FORK DAMPER

Blow out any oil from the oil hole (After ’07: holes) of the fork damper using compressed air.

Wipe off the oil completely from the fork damper.

FORK DAMPER

OIL HOLE

INSPECTION

INSPECTION

SPRING CHAMBER

oil

If you cannot use compressed air, remove the pres­sure release screw on the fork cap.

Hold the fork damper upside down for 10 minutes and drain the oil from the fork damper spring cham­ber.

Tighten the pressure release screw to the specified torque.

TORQUE: 1.2 N-m (0.1 kgf-m, 0.9 Ibf-ft)

FORK DAMPER OPERATION INSPECTION

INSPECTION

• Turn the compression adjuster counterclockwise to the softest position.

• Check the fork damper piston rod sliding surface for damage.

• Apply fork oil to the fork damper piston rod slid­ing surface.

Be careful not to bend or damage the fork damper piston rod when the piston rod is stroked.

Inspect the fork damper operation after air bleeding (page 14-23).

Cover the piston rod end to prevent damage.

Fully stroke the fork damper piston rod by pushing down the fork damper.

Check the fork damper piston rod for smooth opera­tion.

If the fork damper piston rod operation is not smooth, check the piston rod for bends or damage.

Hold the fork damper level while the fork damper piston rod is fully extended and compressed by hand.

FORK DAMPER

INSPECTION

Release the fork damper piston rod then check that it extends to its maximum length.

If the fork damper piston rod does not extend to maximum, bleed the fork damper again.

INSPECTION

Wipe the oil completely off from the fork damper. Compress the fork piston rod 200 — 250 mm (7.9 — 9.8 in) from fully extended and hold the fork damper in an upright position for 10 minutes.

There should be no oil leaking from the fork damper spring chamber and piston rod.

If oil leaks from the spring chamber or piston rod, replace the fork damper assembly.

Hold the fork damper on level ground and release the fork damper piston rod, then check that the pis­ton rod extends to its maximum length.

FORK DAMPER INSTALLATION/PREPARATION

OUTER TUBE/SLIDER

INSPECTION

If the outer tube and slider (fork) have not been dis­assembled, turn the fork upside down for 20 min­utes and drain the oil from the inside of the outer tube and slider completely (7 cc at 20°C/ 68°F).

INSPECTION

Amount of fork oil left in the fork (without damper and spring)

unit: cc

minute

5

10

20

35

55

85 | 145

30/86

7.1

5.9

4.7

4.2

3.5

3.5 3.5

u.

p

20/68

10.6

8.2

7.1

5.9

5.6

4.7 4.7

О

о

10/50

11.8

8.3

7.2

6.2

5.8

4.9 4.8

0/32

12.9

10.6

9.4

8.2

7.9

7.1 I 5.9

If the fork damper has not been disassembled from the outer tube/slider, turn it upside down for 20 min­utes and drain the oil from the inside of the outer tube and slider completely (12 cc at 20°C/ 68°F).

INSPECTION

0°C (32°F)

10°C (50°F)

20°C (68°F)

30°C (86°F)

0 20 40 60

Inverted time

100 120 140 160

INSPECTION

(minutes)

Amount of fork oil left in the fork (within damper and spring)

unit: cc

minute

5

10

ГО

35

55

85

145

LL

o

о

о

30/86

27

15.3

10.6

9.4

8.3

7.9

7.9

20/68

29.4

16.5

11.8

10.6

9.4

8.2

8.2

10/50

28.2

21.4

16.5

15.3

12.9

11.8

11.8

0/32

30.6

22.4

18.8

16.5

16.5

15.3

14.1

LOCK NUT

INSPECTION

Tighten the lock nut fully and measure the length as shown.

STANDARD: 11-13 mm (0.43 — 0.51 in)

Wipe the oil completely off the fork damper.

OUTER TUBE AND SLIDER DISASSEMBLY

OUTER TUBE AND SLIDER DISASSEMBLY

Be careful not to scratch the slider.

Remove the dust seal and stopper ring.

Check that the slider moves smoothly in the outer tube.

If it does not, check the slider for bends or damage, and the bushings for wear or damage (page 14-19).

OUTER TUBE AND SLIDER DISASSEMBLY

BACK-UP RING

Carefully remove the slider bushing by prying the slot with a screwdriver until the bushing can be pulled off by hand.

Remove the following:

— Guide bushing

— Back-up ring

— Oil seal

— Stopper ring

— Dust seal

Using quick successive motions, pull the slider out of the outer tube.

FORK DAMPER DISASSEMBLY

Set the fork damper in a vise with a piece of wood or soft jaws to avoid damage.

Hold the fork damper assembly using the special tool.

TOOL:

Lock nut wrench, 50 mm 07WMA-KZ30100

SLIDER BUSHING

GUIDE BUSHING

DUST SEAL

OUTER TUBE AND SLIDER DISASSEMBLY

Do not damage the slider bushing, especially the sliding surface. To prevent loss of tension, do not open the bushing more than necessary.

SIX POINT SOCKET, 32 mm

OUTER TUBE AND SLIDER DISASSEMBLY

FORK DAMPER

LOCK NUT WRENCH ■ FORK CAP ASSEMBLY

FORK CAP ASSEMBLY

FORK DAMPER

OUTER TUBE AND SLIDER DISASSEMBLY

Remove the fork cap assembly from the fork damper.

NOTE:

• Be careful not to damage the fork cap bushing.

• Do not disassemble the fork cap assembly.

• Replace the fork cap as an assembly if it is dam­aged.

Empty the fork oil from the fork damper by pumping the damper rod several times.

FORK DAMPER

OUTER TUBE AND SLIDER DISASSEMBLY

FRONT WHEEL

REMOVAL

BRAKE DISC COVER

Remove the bolts and brake disc cover.

BOLTS

AXLE HOLDER BOLTS

Raise the front wheel off the ground by placing a workstand or equivalent under the engine.

Remove the axle nut and loosen the left axle holder bolts.

AXLE NUT

AXLE HOLDER BOLTS

TRIPMETER CABLE

LOCK NUT

Loosen the lock nut and disconnect the tripmeter cable.

Loosen the right axle holder bolts.

Be careful not to Remove the axle and front wheel.

oa< age the brake t nQt operate brake lever after removing pads with the disc. {he from whee, To do so wM| cause Acuity in

fitting the brake disc between the pads.

AXLE

INSPECTION

AXLE

AXLE

FRONT WHEEL

Set the axle on V-blocks and measure the runout. Turn the axle and measure the runout using a dial indicator.

Actual runout is 1/2 of the total indicator reading. SERVICE UMIT: 0.20 mm (0.008 in)

WHEEL BEARING

Turn the inner race of each bearing with your finger. The bearings should turn smoothly and quietly.

FRONT WHEEL

WHEEL BEARING

Also check that the bearing outer race fits tightly in the hub.

Replace fhe bearings in pairs.

Replace the bearings if the inner race does not turn smoothly, quietly, or if outer race fits loosely in the hub.

WHEEL RIM

FRONT WHEEL

Check the rim runout by placing the wheel in a truing stand.

Spin the wheel by hand, and read the runout using a dial indicator.

Actual runout is 1/2 the total indicator reading.

SERVICE LIMITS:

Radial: 2.0 mm (0.08 in)

Axial: 2.0 mm (0.08 in)

Check the spokes and tighten any that are loose.

FRONT WHEEL

’05 — ’07 shown: W V

*• /

TRIPMETER GEAR BOX

DISASSEMBLY

FRONT WHEEL

LEFTSIDE COLLAR

’05-’07 shown: BRAKE DISC ■

BOLTS/NUTS

DUST SEAL

Remove the tripmeter gear box.

Remove the left side collar and dust seal.

Remove the brake disc bolts and nuts. Remove the brake disc.

FRONT WHEELReplace the wheel Install the remover head into the bearing. bearings m pairs. From the opposite side of the wheel, install the Do not reuse old remover shaft and drive the bearing out of the bearings, wheel hub.

BEARING REMOVER SHAFT

Remove the distance collar and drive out the other bearing.

TOOLS:

07746-0050600

07GGD-0010100

Bearing remover head, 20 mm Bearing remover shaft

BEARING REMOVER HEAD

ASSEMBLY

LEFT WHEEL BEARING

LEFT DUST SEAL

12 N-m (1.2 kgf-m, 9 Ibf-ft)

RIGHT WHEEL BEARING

DISTANCE COLLAR

FRONT WHEEL

After ’07:

BRAKE DISC

FRONT WHEEL

16 N m (1.6 kgf-m, 12 Ibf-ft) TRIPMETER GEAR BOX

FRONT WHEEL

WHEEL HUB

Place the hub in the center of the rim, and begin the lacing with new spokes.

Adjust the hub position so the distance from the hub left end surface to the side of the rim is 28.0 ±

1. mm (1.10 ± 0.04 in) as shown.

Torque the front spokes in two or three progressive

FRONT WHEEL

SPOKE WRENCH

steps

TOOL:

Spoke wrench, 6.1 mm 07JMA-MR60100

or 07701-0020300 (6.1 mm) or equiv­alent commer­cially available in U. S.A.

TORQUE: 3.68 N m (0.4 kgf-m, 2.7 lbf-ft)

FRONT WHEEL

SETTING RUBBER

VALVE

VALVE NUT

FRONT WHEEL

Install the front rim lock, setting rubber, tube and tire.

Tighten the front rim lock to the specified torque. TORQUE: 12 N m (1.2 kgf m, 9 Ibf ft)

DRIVER

Pack all bearing cavities with grease.

Drive the left wheel bearing in the wheel hub until it is fully seated using special tools.

Replace the wheel bearings in pairs. Do not reuse old bearings

• Install the wheel bearings with the sealed sides toward the outside.

TOOLS:

Driver 07749-0010000

Attachment, 37 x 40 mm 07746-0010200

Pilot, 20 mm 07746-0040500

ATTACHMENT/PILOT

Install the distance collar into place, then drive the right wheel bearing using the same special tools.

Install the brake disc onto the wheel hub with the drive mark facing out.

Install the brake disc bolts and nuts.

Tighten the nuts to the specified torque.

TORQUE: 16 Nm (1.6 kgf m, 12 Ibf ft)

Pack a new left dust seal lip with grease and install it into the hub.

Check the left side collar and tripmeter gear box for wear or damage.

ft LEFT SIDE COLLAR fig

FRONT WHEEL

Pack the tripmeter gear box and dust seal lip with grease.

Install the left side collar to the wheel.

Install the gear box while aligning the trip meter gear tabs of the gear box with the grooves on wheel.

INSTALLATION

O-RING

FRONT WHEEL

Clean the clamping surface of the axle and axle holders.

Be careful not to damage the brake pads with the disc.

Install the front wheel between the fork legs while inserting the disc between the pads, and align the tab of the tripmeter gear as shown.

Check that the tripmeter gear box O-ring is in good condition, replace it if necessary.

Apply thin layer of grease to the axle and insert the axle from the right side.

Install and tighten the front axle nut to the specified torque.

TORQUE: 88 Nm (9.0 kgf m, 65 Ibf ft)

Tighten the left axle holder bolts to the specified torque.

TORQUE: 20 N-m (2.0 kgf m, 15 Ibf-ft)

With the front brake applied, pump the front sus­pension up and down several times to seat the axle and check the front brake operation.

Be sure the fork legs are parallel, then tighten the right axle holder bolts to the specified torque.

TORQUE: 20 N m (2.0 kgf m, 15 lbf-ft)

Connect the tripmeter cable and tighten the lock nut securely.

Install the brake disc cover and bolts. Tighten the bolts to the specified torque.

TORQUE: 13 N m (1.3 kgf m, 10 lbf-ft)

TRIPMETER* ABLE

AXLE HOLDER BOLTS

BRAKE DISC COVER

FRONT WHEEL

BOLTS 7

FORK

REMOVAL

NOTE:

After 107:

FRONT WHEEL

When removing the both fork legs, remove the steering damper to prevent damaging it (page 14­38).

Remove the following:

— Front visor (’05 — ’07: page 3-5, After ’07: page 3­6)

— Front wheel (page 14-8)

Do not suspend the brake caliper from the brake hose. Do not twist the brake hose.

Remove the mounting bolts and front brake caliper.

Do not operate the brake lever after removing the caliper and front wheel. To do so will cause diffi­culty in fitting the brake disc between the brake pad. Remove the bolts and brake hose clamp.

Remove the screws and tripmeter cable clamp.

Remove the bolts and fork protector.

Loosen the fork top bridge pinch bolts.

TOP BRIDGE PINCH BOLTS

FRONT WHEEL

REBOUND ADJUSTER

FRONT WHEEL

When the fork is ready to be disassembled, remove the handlebar and holders (page 14-32) and loosen the fork damper using the following procedure.

FRONT WHEEL

COMPRESSION ADJUSTER

When disassembling the fork leg, turn the rebound and compression adjusters counterclockwise to the softest position to prevent damaging the adjust­ment needle (be sure to record the number of turns from the starting position).

Do not use a crescent or adjustable wrench to loosen the fork damper; it could be damaged

LOCKNUT WRENCH

FORK

FORK DAMPER

FRONT WHEEL

Loosen the fork damper using the special tool, but do not remove it yet.

TOOL:

FRONT WHEEL

BOTTOM BRIDGE PINCH BOLTS

Lock nut wrench, 50 mm 07WMA-KZ30100

Loosen the fork bottom bridge pinch bolts and pull the fork leg down and out.

DISASSEMBLY

Be careful not to scratch the slider and not to damage the dust seal.

FRONT WHEEL

Clean the fork assembly, the sliding surface of the fork slider and the bottom of the slider around the center bolt before disassembling the fork.

Measure the length between the axle holder and outer tube, and record it before disassembling the fork.

’05-’07 shown: FORK DAMPER

LOCK NUT WRENCH

FRONT WHEEL

Hold the outer tube and remove the fork damper using the special tool.

TOOL:

Lock nut wrench, 50 mm 07WMA-KZ30100

OUTER TUBE

Slide the outer tube down onto the axle holder.

FRONT WHEEL

’05 -’07 shown:

OIL HOLE

Drain the fork oil from the fork leg.

Drain the fork oil from the oil hole (After ’07: oil holes) in the fork damper.

Temporarily install the fork damper assembly into

the outer tube. FORK DAMPER ASSEMBLY

FRONT WHEEL

OUTER TUBE

Set the axle holder of the slider in a vise with a piece of wood or soft jaws to avoid damage.

CENTER BOLT

FRONT WHEEL

Do not over-tighren the vise on the axle holder.

Loosen the center bolt.

AXLE HOLDER

FRONT WHEEL

II a piston base is not available, refer to the next step to make an alternative tool.

Push the fork damper out from the slider until the lock nut is fully exposed and install the piston base or mechanic’s stopper tool between the axle holder and lock nut.

TOOL:

Piston base 07958-2500001 or

Fork rod stopper 07AMB-KZ3A100

(U. S.A. only)

FRONT WHEEL

FRONT WHEEL

LOCK NUT

FORK CENTER BOLT

Make the mechanic’s stopper tool from a thin piece of steel (1.0 mm thick) as shown if you do not have a special tool.

Hold the lock nut and remove the fork center bolt from the fork damper.

FRONT WHEELRemove the push rod from the piston rod.

PISTON ROD

FRONT WHEEL

AXLE HOLDER

Be careful not to damage the lock nut end fork center bolt hole.

LOCK NUT

Remove the piston base or mechanic’s stopper tool while pushing the fork cap.

PISTON BASE

’05 — ’07 shown: FORK DAMPER ASSEMBLY

FORK ASSEMBLY

SPRING

FRONT WHEEL

Remove the fork damper assembly from the fork assembly.

Remove the fork assembly from the vise.

Remove the fork spring from the fork assembly.