Removal
Caution: Although not strictly necessary, before removing the forks it is recommended that the fairing and fairing panels are removed (see Chapter 8). This will prevent accidental damage to the paintwork.
1. Remove the front mudguard (see Chapter 8).
2. Remove the front wheel (see Chapter 7). Tie the front brake calipers and hoses back so that they are out of the way.
3. Release the speedometer cable and any wiring from the fork, noting its routing.
4. Working on one fork at a time, slacken the fork clamp bolts in the top yoke (see illustration). If the fork is to be disassembled, or if the fork oil is being changed. It is advisable to slacken the fork top bolt at this stage (see illustration). On XRV750-L to S (1990 to 1995) models, first remove the air valve cap. then depress the valve to release any air under pressure. Note the amount of protrusion of the fork above the top yoke.
Slackening the fork clamp bolts in the top yoke before slackening the fork top bolts releases pressure on the top bolt This makes it much easier to remove and helps to preserve the threads.
6.4a. Slacken the fork clamp bolts (arrowed) in the top yoke...
6.4b ...and if required the fork top bolt
5. Slacken the fork clamp bolts in the bottom yoke, and remove the fork by twisting it and pulling it downwards (see illustrations).
6.5a. Bottom yoke fork clamp bolts (arrowed)
6.5b. Draw the fork down and out of the yokes
If the fork legs are seized in the yokes, spray the area with penetrating oil and allow time for it to soak in before trying again.
Installation
6. Remove all traces of corrosion from the fork tube and the yokes. Slide the fork up through the bottom yoke and into the top yoke, making sure it passes through the cable tie(s) and all cables, hoses and wiring are routed on the correct side of the fork (see illustration 6.5b).
7. Set the top of the fork tube (not the top of the fork top bolt) flush with the top surface of the top yoke (see illustration). Make sure it is the same on both sides.
6.7. Set the fork height as shown, making sure it is the same on both sides
8. Tighten the fork clamp bolts in the bottom yoke to the torque setting specified at the beginning of the Chapter (see illustration 6.5a). If the fork has been dismantled or if the fork oil was changed, tighten the fork top bolt to the specified torque setting (see illustration). Now tighten the fork clamp bolts in the top yoke to the specified torque (see illustration 6.4a).
6.8. Tighten the fork top bolt to the specified torque setting
9. If the forks were disassembled, push the gaiter up the fork tube until contacts the underside of the bottom yoke, then tighten its clamp screw (see illustration).
6.9. Push the gaiter up against the yoke and tighten the clamp screw (arrowed)
10. Install the front wheel (see Chapter 7) and the front mudguard (see Chapter 8). Make sure the speedometer cable is properly routed and secure in it s guides.
11. Check the operation of the front forks and brakes before taking the machine out on the road.