Warning:
- 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.
- When assembling the front fork leg, be sure to replace the following parts:
- Oil seal
- Dust seal
- O-ring
- Before assembling the front fork leg, make sure all of the components are clean.
1. Install:
- Damper rod assembly "1"
- Inner tube "2"
Notice: 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 M1 or equivalent.
3. Tighten:
- Damper rod assembly
Damper rod assembly 75 Nm (7.5 m·kgf, 54 ft·lbf).
Tighten the damper rod assembly with the damper rod holder "1".
Damper rod holder 90890-01506 YM-01506.
4. Install:
- Dust seal "1" New
- Oil seal clip "2" New
- Oil seal "3" New
- Washer "4"
Notice: Make sure the numbered side of the oil seal faces bottom side.
- 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:
- Outer tube (to the inner tube)
6. Install:
- Washer
- Oil seal "1" (with the fork seal driver "2")
Fork seal driver 90890-01442.
Adjustable fork seal driver (36- 46 mm) YM-01442.
7. Install:
- Oil seal clip "1"
Adjust the oil seal clip so that it fits into the outer tube's groove.
8. 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.
9. Install:
- Rod puller "1"
- Rod puller attachment "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.
10. Fully compress the front fork leg.
11. Fill:
- Front fork leg (with the specified amount of the recommended fork oil)
Quantity 528.0 cm³ (17.85 US oz, 18.62 Imp.oz).
Recommended oil.
Suspension oil M1.
Notice:
- 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.
12. After filling the front fork leg, slowly stroke the damper rod "1" up and down (at least ten times) to distribute the fork oil.
Be sure to stroke the damper rod slowly because the fork oil may spurt out.
13. Before measuring the fork oil level, wait ten minutes until the oil has settled and the air bubbles have dispersed.
Be sure to bleed the front fork leg of any residual air.
14. 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.
Level 117.0 mm (4.61 in).
15. Install:
- Lower spring seat "1"
- Forkspring "2"
- Upper spring seat "3"
- Spacer "4"
- Nut "5"
- Damper adjusting valve spring "6"
- Damper adjusting valve "7"
- Damper adjusting rod "8"
- Washer "9"
- Cap bolt "10" (with O-ring)
- a. Remove the rod puller attachment.
- b. Install the under spring seat.
- c. Install the fork spring.
Install the spring with the smaller pitch "a" facing up "A".
- d. Install the upper spring seat.
- e. Install the spacer.
- f. Install the nut.
- g. Reinstall the rod puller attachment.
- h. Press down on the spacer with the fork spring compressor "1".
- i. Pull up the rod puller and install the rod holder "2" between the nut "3" and the spacer "4".
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.
Fork spring compressor 90890-01441 YM-01441.
Rod holder 90890-01434.
Damper rod holder double ended YM-01434.
Use the side of the rod holder that is marked "B".
- j. Remove the rod puller and rod puller attachment.
- k. Install the nut "1" all the way onto the damper rod assembly.
- l. Install the damper adjusting valve spring, the damper adjusting valve and the damper adjusting rod.
- m. Install the washer and cap bolt, and then finger tighten the cap bolt.
- n. Hold the nut and tighten the spring preload adjusting bolt "2" into the cap bolt to specification.
Warning: Always use a new cap bolt O-ring.
Notice: When tightening the spring preload adjusting bolt "2" into the cap bolt, be sure not to break the projections "a" on the cap bolt collar "3".
Hold the nut "1" using a proper tool that has a thickness "b" of 4.0 mm (0.16 in) or less.
Nut and cap bolt 25 Nm (2.5 m·kgf, 18 ft·lbf).
o. Remove the rod holder and fork spring compressor.
16. Install:
- Cap bolt (to the outer tube)
- Temporarily tighten the cap bolt.
- When to tighten the cap bolt to the specified torque is after installing the front fork leg to the vehicle and tightening the lower bracket pinch bolts.