Front fork removal (each fork leg)
Loosen the front axle nut (see Front wheel removal in the Wheels/Tires chapter).
Using the jack [A] under the frame pipes, and a commercially available jack [B] under the engine, lift the front wheel off the ground until the rear wheel touches the ground.
- Special Tool - Jack: 57001-1238
Caution! Be sure to put the rear wheel on the ground when removing the front fork, or the motorcycle may fall over. The motorcycle could be damaged.
Warning! Be sure to put the rear wheel on the ground when removing the front fork, or the motorcycle may fall over. It could cause an accident and injury.
Remove:
- Front Fender (see Front fender removal in the Frame chapter)
- Front Wheel (see Front wheel removal in the Wheels/Tires chapter)
- Headlight Unit (see Headlight body removal in the Electrical System chapter)
Remove:
- Turn Signal Light Lead Connectors [A]
- Lower Turn Signal Bracket Bolts [B]
- Side Turn Signal Bracket Bolts (Both Sides) [C]
- Brake Hose (from the clamp) [D]
- Turn Signal (with the Bracket)
Remove:
- Steering Stem Head (see Steering stem removal in the Steering chapter)
- Front Fork Upper Covers [A]
- Front Fork Lower Clamp Bolts [B]
With a twisting motion, work the fork leg down and out.
Note. Of the fork is tight, tap lightly around the base of the stem head with a plastic mallet.
Front fork installation
Install the stopper [A] so that the distance between the fork top end [B] and the upper surface [C] of the stopper is 250.6 mm (9.866 in.) [D].
- Torque - Front Fork Upper Cover Stopper Bolt: 4.2 N·m (0.43 kgf·m 37 in·lb)
Insert the washer, rubber seat and fork lower cover to the inner tube.
Turn the lower clamp bolt clockwise posing the fork leg upward fully.
Install the fork so that the top end [A] of the inner tube is flush with the upper surface of the steering stem head.
Tighten:
- Lower Front Fork Clamp Bolt: 34 N·m (3.5 kgf·m 25 ft·lb)
- Upper Front Fork Clamp Bolt: 20 N·m (2.0 kgf·m 15 ft·lb)
Install the removed parts.
Check the front brake effectiveness after installation.