Disassembly
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.
Note: Before removing the forks, slacken the top cap a little to allow easier removal during strip-down. The fork seals can be renewed without removal of the damping cylinder. Unless removal of the damping cylinder is necessary, omit steps 16 and 17 of this procedure. If the damping cylinder is to be removed, loosen the lower damping cylinder bolt before removing the forks.
1. Remove the forks (see page 13-5).
2. Very gently clamp the fork in the soft jawed vice to prevent it from turning, hold the outer tube, then unscrew the top cap from the outer tube.
1. Fork; 2. Soft jaws; 3. Top cap
Caution: ever tightly clamp the outer tube as this will cause the tube to permanently distort. A distorted tube is not serviceable and must be replaced.
Note: The top cap is not under spring tension and will not spring upwards when the threads disengage.
3. Slacken the locknut, unscrew and remove the top cap. If necessary, remove the О-ring seal from the top cap assembly.
4. Holding the inner and outer tubes together, invert the fork and pour out the fork oil into a suitable container. Pump the damper rod to remove all the oil.
5. Return the fork to the soft jawed vice.
Warning: While compressing the fork spring always wear protective equipment for the face and eyes and never stand directly above or look directly down on the fork. If the spring compressor should dislodge or detach, the resulting release of spring tension could cause parts to fly off resulting in injury to the user.
6. Tiger 800XC only: Fit tool T38.80067 over the spring spacer. Position the two adjustable arms to the holes in the spring spacer. Screw in the arms until they positively engage in the spring spacer holes.
7. Using tool T3880067, manually compress the fork spring and remove the split collar from below the damper locknut.
1. Damper locknut; 2. Tool T3880067; 3. Split collar
8. Remove tool T3880067 from the spring spacer.
Note: On Tiger 800 models, an assistant may be required to remove the split collar.
9. Tiger 800 only: Tool T3880067 is not required; the spring can be compressed by gripping the spring collar by hand and the split collar removed.
Warning: While compressing the fork spring always wear protective equipment for the face and eyes and never stand directly above or look directly down on the fork. If the spring compressor should dislodge or detach, the resulting release of spring tension could cause parts to fly off resulting in injury to the user.
Note:
- On Tiger 800 models, the spring has a smaller coil diameter at both ends, and can be fitted either way up.
- On Tiger 800XC models, the spring has a smaller coil diameter at its upper end. Note the orientation of the spring before removal.
10. Remove the spring spacer and spring.
1. Washer; 2. Spring spacer (Tiger 800 shown); 3. Spring; 4. Damper rod
Note: To help with identification of the service tools, tool T3880158 has a single groove turned on its outside circumference. Tool T3880154 does not have a groove.
11. Fit both halves of tool T3880158 (for Tiger 800 models) or tool T3880154 (for Tiger 800XC models) to the outer tube as shown below and hold in position.
1. Outer tube; 2. Tool T38801S8 (Tiger 800) or T38801S4 (Tiger 800XC)
12. Invert and mount the fork assembly to tool T3880153.
1. Tool T38801S3; 2. Tool T38801S8 (Tiger 800) or T38801S4 (Tiger 800XC)
13. Raise the inner tube and remove the dust seal from the outer tube.
1. Dust seal
14. Remove the circlip.
1. Circlip
15. Remove the fork from the tool and, using a slide hammer action to release the oil seal and bushes from the outer tube, separate the inner and outer tubes leaving the seals and bushes in place on the inner tube.
Note: the relative positions and orientation of all bushes and seals before removal.
1. Inner tube; 2. Outer tube
16. To allow the removal of the seals and bushes, carefully remove the upper bush from the inner tube.
1. Inner tube; 2. Upper bush
17. If removal of the damping cylinder is required, unscrew the damping cylinder bolt from the bottom of the lower fork, then slide the damping cylinder out of the inner tube. Collect the centering collar from the lower end of the damping cylinder.
1. Damping cylinder
Inspection
1. Inspect the inner tube for stone chips, scoring, scratches, excessive wear and any other damage. Renew as necessary.
Note: Small inclusions in the inner tube may be removed using a fine grade stone or similar.
2. Inspect the spring for damage, cracks and deformation. Renew the spring if necessary.
3. Inspect all the bushes and seals for damage. Renew any damaged items if necessary.
Assembly
Warning: The front forks comprise many precision machined parts. Total cleanliness must be observed at all times and assembly must take place in a dirt/dust-free environment. Dirt ingress may cause damage to the fork parts, leading to incorrect operation, instability, loss of control or an accident.
Note: If the damping cylinder has not been removed, omit steps 1 to 3.
1. Fit the centering collar to the lower end of the damping cylinder.
2. Fit the damping cylinder to the inner tube.
3. Clean the threads of the damping cylinder bolt and fit a new sealing washer. Prevent the cylinder from turning while tightening the damping cylinder securing bolt to 20 Nm.
Note: To help with identification of the service tools, tool T3880158 has a single groove turned on its outside circumference. Tool T3880154 does not have a groove.
4. Fit both halves of tool T3880158 (Tiger 800 models) or tool T3880154 (Tiger 800XC models) to the outer tube as shown below and hold in position.
1. Outer tube; 2. Tool T3880158 (Tiger 800) or T3880154 (Tiger 800XC)
5. Invert and position the fork tube outer to tool T3880153.
1. Outer tube; 2. Tool T3880158 (Tiger 800) or T3880154 (Tiger 800XC); 3. Tool T3880153
6. Apply a smear of fork oil to the bushes and seals.
7. Position the seals and bushes to the inner tube as noted prior to removal. Ensure the seal (item 3) is positioned with the text end facing the circlip. Use a new circlip.
1. Dust seal; 2. Circlip; 3. Seal; 4. Washer; 5. Lower bush; 6. Upper bush
8. Fit the upper bush to the fork inner tube.
9. Position the inner tube assembly to the outer, ensuring that the oil and dust seal lips do not become damaged.
10. Using the narrow end of tool T3880003 (Tiger 800 models) or T3880157 (Tiger 800XC models), guide the lower bush, washer and seal into place.
1. Tool T3880003 (Tiger 800) or T3880157 (Tiger 800XC); 2. Seal; 3. Washer; 4. Lower bush; 5. Tool T3880153; 6. Tool T3880158 (Tiger 800) or T3880154 (Tiger 800XC)
11. Retain the bush, washer and seal with a new circlip.
1. Dust seal; 2. Circlip; 3. Tool T3880153
12. Position the dust seal to the outer tube.
13. Invert tool T3880003 (Tiger 800 models) or T3880157 (Tiger 800XC models) and, using hand pressure only, push the dust seal squarely into the outer tube.
14. Fill the fork with oil (see page 13-7).
15. Position the fork assembly as for compression of the fork spring during strip down.
Caution: If removed, the damping rod locknut must be fitted with the flat face facing to the top of the fork. The slightly tapered face must face the fork spring. Incorrect orientation may lead to a loosening of the locknut.
16. Tiger 800: Re-thread the damper cylinder rod locknut leaving 10.5 mm of thread exposed above the nut (dimension A below).
17. Tiger 800XC: Re-thread the damper cylinder rod locknut leaving 12 mm of thread exposed above the nut (dimension A below).
Damper Cylinder Rod Nut Setting
18. Refit the fork spring, close wound end uppermost, spring spacer and washer.
1. Washer; 2. Spring spacer miger 800 shown; 3. Spring; 4. Damper rod
19. Attach tool 3880085-T0301 to the threads of the damper rod and pull the damper upwards.
Warning: While compressing the fork spring always wear protective equipment for the face and eyes and never stand directly above or look directly down on the fork. If the spring compressor should dislodge or detach, the resulting release of spring tension could cause parts to fly off resulting in injury to the user.
20. Tiger 800XC only: Refit tool T3880067 as previously described, compress the fork spring and refit the split collar below the damper rod nut. Remove tool T388006Z
1. Damper locknut; 2. Tool T3880067; 3. Spring holder (part of T3880067)
Note: On Tiger 800 models, an assistant may be required to install the split collar.
21. Tiger 800 only: Tool T3880067 is not required; the spring can be compressed by gripping the spring collar by hand and the split collar installed with the aid of an assistant.
22. Remove tool 3880085-T0301 from the damper rod.
23. Fit a new O-ring to the top cap.
24. Refit the top cap to the damper rod.
25. Hold the top cap while tightening the damper rod locknut to 20 Nm.
26. Lubricate the O-ring on the top cap with a smear of fork oil then screw the top cap fully into the inner tube.
27. Tighten the top cap to 35 Nm.
Note: lt is much easier to tighten the top cap when the fork has been refitted.
28. Refit the fork (see page 13-6).