Left Hand Front Fork - Assembly

Warning - Suspension - Front forks have precision machined parts

warning
The front forks comprise of 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 motorcycle control and an accident.
  1. Lubricate the oil seal, upper and lower bushes for the inner tube with clean fork oil.
  2. Install service tool T3880642 to the fork inner tube. Ensure the tool is not damaged and that it covers the bush groove fully.
  3. Front Fork inner tube and seal guide tool (ccup_4.svg)
    1. Fork inner tube

    2. T3880642 - Fork Seal Guide/Protector

  4. Slide a new dust seal on to the fork inner tube as noted for removal.
  5. Slide the circlip and a new oil seal on to the fork inner tube as noted for removal.
  6. Slide the washer and a new lower bush onto the inner tube.
  7. Remove service tool T3880642 from the fork inner tube.
  8. Fit a new upper bush to the fork inner tube.
  9. Fork bushes and seals
    1. Upper bush

    2. Lower bush

    3. Washer

    4. Oil seal

    5. Circlip

    6. Dust seal

    7. Fork inner tube

  10. Insert the fork inner tube assembly into the fork outer tube.
  11. Using the narrow end of service tool T3880003, guide the lower bush, washer and oil seal into place.
  12. Front fork oil seal
    1. T3880003 - Front Fork Seal Installer

    2. Oil seal

    3. Fork inner tube

    4. Fork outer tube

  13. Secure the oil seal in position with the circlip, ensuring it is correctly located in its groove.
  14. Position the dust seal to the outer tube.
  15. Invert service tool T3880003 and, using hand pressure only, push the dust seal squarely into the outer tube.
  16. Front fork dust seal
    1. T3880003 - Front Fork Seal Installer

    2. Dust seal

  17. Return the fork to an upright position, with the lower end of the fork inner tube secure in service tool T3880171.
  18. Refill the fork with new oil (see Fork Oil Change - Oil Refilling).
  19. Fit the spring into the fork inner tube as noted during removal.
  20. Fork Spring (cjrk_1.svg)
    1. Spring

    2. Fork outer tube

  21. If removed, fit a new O-ring to the top cap.
  22. If removed, screw the top cap fully onto the joint rod.
  23. Hold the top cap while tightening the lock nut to 20 Nm.
  24. note
    When fitting the fork top cap and joint rod assembly, care must be taken not to damage the top ring of the joint rod assembly.
  25. With the fork fully compressed use service tool T3880367 to fit the fork joint rod assembly to the inner tube.
  26. Top cap/damper assembly removal, cjqi_1
    1. T3880367 - Wrench, Damper Cylinder, 33mm

    2. Top cap

    3. Joint rod

    4. Fork outer tube

  27. Remove the fork from service tool T3880171 and transfer to a soft jawed vice.
  28. Forks in vice_1 (ckwm_1)
    1. Front fork assembly

    2. Soft jaws

  29. With the lower end of the fork inner tube secure in the vice, tighten the joint rod assembly to 90 Nm using a torque wrench fitted with a suitable crow foot spanner adapter (see Use of Crow Foot Spanner Adapters with Torque Wrenches).
  30. Lubricate the O-ring on the top cap with a smear of clean fork oil then screw the top cap fully into the fork outer tube.
  31. caution
    Before tightening, cover the top cap with a suitable masking tape to protect its anodized finish from tool damage.
  32. Tighten the top cap to 35 Nm.
  33. note
    It is much easier to tighten the top cap when the fork has been refitted.