Right 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.
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 fork 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.
  4. Lubricate the oil seal, upper and lower bushes for the inner tube with clean fork oil.
  5. Install service tool T3880642 to the fork inner tube. Ensure the tool is not damaged and that it covers the bush groove fully.
    6. Front Fork inner tube and seal guide tool (ccup_4.svg)

    1. Fork inner tube

    2. T3880642 - Fork Seal Guide/Protector

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

    1. Upper bush

    2. Lower bush

    3. Washer

    4. Oil seal

    5. Circlip

    6. Dust seal

    7. Fork inner tube

  11. Insert the fork inner tube assembly into the fork outer tube.
  12. Using the narrow end of service tool T3880003, guide the lower bush, washer and oil seal into place.
    13. 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

  16. Return the fork to an upright position, with the lower end of the fork inner tube secure in service tool T3880171.
  17. Refill the fork with new oil (see Fork Oil Change - Oil Refilling).
  18. Position the fork assembly as for compression of the fork spring during disassembly.
  19. Make sure that the damper rod lock nut is screwed fully onto the threads of the damper rod.
  20. Fit the spring, washer and spring spacer into the fork inner tube as noted during removal.
    21. Fork spring, washer and spring spacer, cdno_3

    1. Spring spacer

    2. washer

    3. Spring

    4. Damper rod lock nut

  21. Attach service tool T3880085 to the threads of the damper rod and pull the damper upwards.
    22. 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.
  22. Fit service tool T3880067 over the spring spacer. Position the two adjustable arms to the spring spacer. Screw in the arms until they positively engage in the spring spacer holes.
    23. note
    An assistant may be required to install the split collar and top cap.
  23. Using service tool T3880067, manually compress the fork spring and with the aid of an assistant, fit the split collar below the damper lock nut.
    24. Compress the fork spring, cgyh_1

    1. Damper lock nut

    2. T3880067 - Fork Spring Compressor

    3. Split collar

  24. Remove service tool T3880085 from the damper rod.
  25. Fit a new O-ring to the top cap.
  26. Screw the top cap fully onto the damper rod.
  27. Compress the fork spring using service tool T3880067 and with the aid of an assistant, hold the top cap while tightening the damper rod lock nut to 20 Nm.
  28. Remove service tool T3880067 from the spring spacer.
  29. Lubricate the O-ring on the top cap with a smear of clean fork oil then screw the top cap fully into the outer tube.
    30. caution
    Before tightening, cover the top cap with a suitable masking tape to protect its anodized finish from tool damage.
  30. Tighten the top cap to 35 Nm.
    31. note
    It is much easier to tighten the top cap when the fork has been refitted.
  31. Refit the fork assembly (see Front Fork - Installation).