Fork oil level (fork fully compressed)
1. Fill the fork with SAE 5w (or Kayaba KHL15-10 fork oil until the oil level is slightly above the recommended level. Alternatively add 667cc of oil if filling a completely empty fork.
2. Pump the fork assembly and damper several times to expel any trapped air then fully compress the fork and support it in an upright position. Leave the fork for a few minutes to allow the oil level to stabilise.
3. Set the scale on tool 3880160-T0301 to the specified level (dimension A below).
1. Tool 3880160-T0301; 2. Adjuster plate; 3. Scale area; 4. Hole (zero position)
Note: Zero level on the tool is set at the small exit hole in the side of the scale tube, NOT AT THE END TIP. Do not attempt to block this side-hole, as this will cause the final fluid level to be incorrect.
4. Insert the scale end of the tool into the fork inner tube.
5. Hold the tool adjuster plate level with the upper surface of the fork outer tube and draw fluid into the syringe until fluid flow ceases (empty the syringe if the body becomes full before fluid flow stops).
6. The fluid level in the fork is now set to the height set on the tool scale. Check the tool scale setting and repeat the process if incorrectly set.
Warning! Incorrect oil levels, particularly over filling, can result in damage to the fork seals. Damaged fork seals are a dangerous riding condition that can lead to loss of motorcycle control and an accident.
7. Position the fork assembly as for compression of the fork spring during strip down.
8. Insert the fork spring and spring cap to the outer tube.
9. Attach tool 3880085-T0301 to the threads of the damper rod and pull the damper upwards.
1. Tool 3880085-T0301
10. Refit the spring spacer.
Warning! While recompressing the fork spring and while the spring holder is in place always wear protective equipment for the face and eyes and never stand directly above or look directly down onto the fork. If the spring compressor or holder should dislodge or detach, the resulting release of spring tension could cause parts to fly off resulting in injury to the user.
11. Refit tool T3880067 as previously described, compress the fork spring and refit the spring holder.
1. Tool T3880067; 2. Spring holder
12. Refit the damping rod locknut leaving 15.5 mm of thread and rod exposed above the nut.
13. Refit the top cap to the damper rod.
14. Hold the top cap while tightening the damper rod locknut to 16 Nm.
Warning! While recompressing the fork spring and while the spring holder is in place always wear protective equipment for the face and eyes and never stand directly above or look directly down onto the fork. If the spring compressor or holder should dislodge or detach, the resulting release of spring tension could cause parts to fly off resulting in injury to the user.
15. Recompress the spring to remove the spring holder.
16. Lubricate the О-ring on the top cap with a smear of fork oil then screw the top cap fully into the inner tube.
17. Tighten the top cap to 30 Nm.
Note: It is much easier to tighten the top cap when the fork is securely clamped in the bottom yoke.