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.
- Lubricate the oil seal, upper and lower bushes for the inner tube with clean fork oil.
- Install service tool T3880642 to the fork inner tube. Ensure the tool is not damaged and that it covers the bush groove fully.
Fork inner tube
T3880642 - Fork Seal Guide/Protector
- Slide a new dust seal on to the fork inner tube as noted for removal.
- Slide the circlip and a new oil seal on to the fork inner tube as noted for removal.
- Slide the washer and a new lower bush onto the inner tube.
- Remove service tool T3880642 from the fork inner tube.
- Fit a new upper bush to the fork inner tube.
Upper bush
Lower bush
Washer
Oil seal
Circlip
Dust seal
Fork inner tube
- Insert the fork inner tube assembly into the fork outer tube.
- Using the narrow end of service tool T3880003, guide the lower bush, washer and oil seal into place.
T3880003 - Front Fork Seal Installer
Oil seal
Fork inner tube
Fork outer tube
- Secure the oil seal in position with the circlip, ensuring it is correctly located in its groove.
- Position the dust seal to the outer tube.
- Invert service tool T3880003 and, using hand pressure only, push the dust seal squarely into the outer tube.
T3880003 - Front Fork Seal Installer
Dust seal
- Return the fork to an upright position, with the lower end of the fork inner tube secure in service tool T3880171.
- Refill the fork with new oil (see Fork Oil Change - Oil Refilling).
- Fit the spring into the fork inner tube as noted during removal.
Spring
Fork outer tube
- If removed, fit a new O-ring to the top cap.
- If removed, screw the top cap fully onto the joint rod.
- Hold the top cap while tightening the lock nut to 20 Nm.
- With the fork fully compressed use service tool T3880367 to fit the fork joint rod assembly to the inner tube.
T3880367 - Wrench, Damper Cylinder, 33mm
Top cap
Joint rod
Fork outer tube
- Remove the fork from service tool T3880171 and transfer to a soft jawed vice.
Front fork assembly
Soft jaws
- 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).
- 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.
- Tighten the top cap to 35 Nm.
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.
caution
Before tightening, cover the top cap with a suitable masking tape to protect its anodized finish from tool damage.
note
It is much easier to tighten the top cap when the fork has been refitted.
Refit the fork assembly (see Front Fork - Installation).