Removal
Warning: Before starting work, ensure the motorcycle is stabilised and adequately supported. This will help prevent it from falling and causing injury to the operator or damage to the motorcycle.
1. Raise and support the front of the motorcycle.
2. Remove the front wheel (see page 15-10).
3. Remove the front mudguard (see page 16-19 Tiger 800 for and 16-20 for Tiger 800XC).
4. Detach and support the front brake calipers (see page 14-16).
Warning: Never allow the brake calipers to hang on the brake hoses as this may damage the hoses. A damaged brake hose can cause a reduction in braking efficiency leading to loss of motorcycle control and an accident.
Note: If the forks are to be dismantled, slacken the fork top cap, and if the damper cylinder is to be removed, slacken the lower damper cylinder bolt.
5. Release the fixing and detach the brake hose from the clip on the fork leg.
1. Brake hose; 2. Brake hose clip; 3. Fixing
6. Slacken the top yoke clamp bolts.
1. Top yoke clamp bolts
Caution: Care must be taken when removing the forks, to ensure that the outer surfaces do not become scratched.
7. Slacken the bottom yoke clamp bolts.
1. Bottom yoke clamp bolts
8. Using a downward, twisting action, withdraw the forks from between the yokes.
Installation
1. Position the forks within the yokes so that the lip of the outer tube, not the top cap, is 4 mm above the upper surface of the top yoke.
1. Outer tube; 2. Top cap; 3. Top yoke
2. Tighten the bottom yoke clamp bolts to 20 Nm.
3. Tighten the top yoke clamp bolts to 20 Nm.
Note: If the forks have been dismantled, tighten the fork top caps to 35 Nm, and if removed, the lower damper cylinder bolt to 20 Nm.
4. Refit the front mudguard (see page 16-21 for Tiger 800 and 16-21 for Tiger 800X).
5. Position the brake hose to the fork leg clip and secure with the bolt, tightening to 6 Nm.
1. Brake hose; 2. Brake hose clip; 3. Fixing
6. Install the front wheel (see page 15-10).
7. Refit the front brake calipers (see page 14-18).
8. Lower the motorcycle to the ground and park it on the side stand.