Warnings!
- Make sure the oil levels in both front fork legs are equal.
- Uneven oil levels can result in poor handling and a loss of stability.
Notes:
- When assembling the front fork leg, be sure to replace the following parts:
- Oilseal
- Dust seal
- Before assembling the front fork leg, make sure all of the components are clean.
1. Install:
- Damper rod assembly «1»
- Inner tube «2»
- Damper rod assembly bolt
- Copper washer
Caution! For the damper rod assembly, the right side is used for the rebound operation and left side for the compression. Pay attention not to mistake the right and left.
Note: The left side (for the compression) damper rod assembly has the four holes of oil path, unlike the right side.
Caution! Allow the damper rod assembly to slide slowly down the inner tube «2» until it protrudes from the bottom of the inner tube. Be careful not to damage the inner tube.
2. Lubricate:
- Inner tube’s outer surface
Recommended oil: Suspension oil 01 or equivalent.
3. Tighten:
- Damper rod assembly bolt «1»
Damper rod assembly bolt: 23 Nm (2.3 m·kg, 17 ft·lb) LOCTITE®.
Note: While holding the damper rod assembly with the damper rod holder «2», tighten the damper rod assembly bolt.
Damper rod holder: 90890-01423.
Damping rod holder: YM-01423.
4. Install:
- Dust seal «1»
- Oil seal clip «2»
- Oil seal «3»
- Washer «4»
Caution! Make sure the numbered side of the oil seal faces up.
Notes:
- Before installing the oil seal, lubricate its lips with lithium-soap-based grease.
- Lubricate the outer surface of the inner tube with fork oil.
- Before installing the oil seal, cover the top of the front fork leg with a plastic bag to protect the oil seal during installation.
5. Install:
- Oil seal «1» (with the fork seal driver «2»)
Fork seal driver: 90890-01442.
Adjustable fork seal driver (36-46 mm): YM-01442.
6. Install:
- Oil seal clip «1»
Note: Adjust the oil seal clip so that it fits into the outer tube’s groove.
7. Install:
- Dust seal «1» (with the fork seal driver weight «2»)
Fork seal driver: 90890-01442.
Adjustable fork seal driver (36-46 mm): YM-01442.
8. Install:
- Rod puller «1»
- Rod puller attachment (M 10) «2» (onto the damper rod «3»)
Rod puller: 90890-01437.
Universal damping rod bleeding tool set: YM-A8703.
Rod puller attachment (M10): 90890-01436.
Universal damping rod bleeding tool set: YM-A8703.
9. Fill:
- Front fork leg (with the specified amount of the recommended fork oil)
Quantity: 539.0 cm3 (18.22 US oz) (19.01 lmp.oz).
Recommended oil: Suspension oil 01 or equivalent.
Cautions!
- Be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance.
- When disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork.
Note: Be sure to bleed the front fork.
10. After filling the front fork leg, slowly stroke the damper rod «1» up and down (at least ten times) to distribute the fork oil.
Note: Be sure to stroke the damper rod slowly because the fork oil may spurt out.
11. Before measuring the fork oil level, wait ten minutes until the oil has settled and the air bubbles have dispersed.
Note: Be sure to bleed the front fork leg of any residual air.
12. Measure:
- Front fork leg oil level «a» (from the top of the outer tube, with the outer tube fully compressed and without the fork spring)
Out of specification → Correct.
Front fork leg oil level: 96 mm (3.78 in).
13. Install:
- Nut «1»
- Fork spring«2»
- Spacer «3»
- Damper adjusting rod «4»
- Cap bolt «5»
a. Remove the rod puller and adapter.
b. Install the nut.
c. Install the fork spring and spacer.
Note: Install the spring with the smaller pitch «a» facing up «A».
d. Press down in the spacer with the fork spring compressor «1»
e. Pull up the rod puller and install the rod holder «2» between the damper adjusting rod locknut «3» and the spacer «4».
Note: Use the side of the rod holder that is marked
Fork spring compressor: 90890-01441 YM-01441
Rod holder: 90890-01434
Damper rod holder double ended: YM-01434
f. Remove the rod puller and the rod puller attachment.
g. Install the nut «1» and position it as specified «b».
Distance «b»: 12 mm (0.47 in).
h. Set the cap bolt distance «c» to specification.
Distance «c»: 13 mm (0.51 in).
i. Install the damper adjusting rod and cap bolt, and then finger tighten the cap bolt.
j. Hold the cap bolt and tighten the damper adjusting rod locknut to specification.
Damper adjusting rod locknut: 15 Nm (1.5 m·kg, 11 ft·lb).
k. Remove the rod holder and fork spring compressor.
Warnings!
- The fork spring is compressed.
- Always use a new cap bolt O-ring.