Front Fork Inspection
A. Inner Tube
NOTICE
If the inner tube is badly bent or creased, replace it. Excessive bending, followed by subsequent straitening, can weaken the in- ner tube.
Front Fork Adjustment
Any of the following front fork adjustments should be made to tune the front suspension to the rider’s weight and the condition of the track.Basically, there are six adjustments you can make to the front fork.
NOTICE
The right and left fork tubes must be adjusted evenly.
Air Pressure Adjustment
The standard air pressure in the front fork legs is atmospheric (0 kPa, 0 kgf/cm?, 0 psi). Air pressure in the fork legs increase with normal use, so the fork action stiffens during operation. Release air pres- sure from the fork legs prior to each race through the pressure relief screw located in each front fork cap. Make sure the front forks are fully extended with the front wheel off the ground when releasing the pres- sure.
Tightening Torque
Pressure Relief Screws: 1.3 Nm (0.13 kgf m, 12 in-lb)
A. Pressure Relief Screw
Rebound Damping Adjustment
NOTICE
Do not force the rebound damping adjuster beyond the fully seated position, or the adjusting mechanism may be damaged.
A. Rebound Damping Adjuster
Rebound Damping Adjuster Settings
A. Seated Position (Adjuster Turned Fully Clockwise)
B. Softer (Counterclockwise)
C. Harder (Clockwise)
D. Standard Setting (KX252C)
E. Standard Setting (KX252D)
Number of turns counterclockwise usable range 20 clicks or more.
Counterclockwise from the fully seated position
Compression Damping Adjustment
To adjust the compression damping, turn the ad- juster on the each front fork cylinder valve with a flat tip screwdriver. Adjust the compression damp- ing to suit your preference under certain conditions.
NOTICE
Do not force the compression damping ad-juster beyond the fully seated position, or the adjusting mechanism may be damaged.
A. Compression Damping Adjuster
Compression Damping Adjuster Settings
A. Seated Position (Adjuster Turned Fully Clockwise)
B. Softer (Counterclockwise)
C. Harder (Clockwise)
D. Standard Setting (Kx252C)
E. Standard Setting (Kx252D)
Number of turns counterclockwise usable range-23 clicks or more.
Standard Compression Damping Adjuster Setting
Counterclockwise from the fully seated position
Front Fork Oil Change
Thoroughly clean the fork before disassembly.
NOTICE
Be careful not to scratch the inner tube and not to damage the dust seal. Avoid scratching or damaging the inner tube or the dust seal. Use a mild detergent and sponge out dirt with plenty of water.
A. Front Fork Clamp Bolts (Upper)
NOTE
NOTE
Do not take off the top plug.
A. Plastic Bag
B. Front Fork Top Plug
C. Top Plug Wrench, 49 mm (Special Tool: 57001-1653)
A. Front Axle Nut
B. Left Front Axle Clamp Bolts (Loosen)
A. Brake Caliper
B. Front Caliper Mounting Bolts
C. Brake Hose Clamps
D. Brake Hose Clamp Mounting Bolts
E. Fork Protector
F. Fork Protector Mounting Bolts
NOTICE
Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place blocks under the wheel so the disc does not touch the ground.
A. Right Front Axle Clamp Bolts (Loosen)
B. Front Axle
C. Collar
D. Fork Protector
Loosen the front fork clamp bolts (lower).
A. Front Fork Clamp Bolts (Lower)
Remove the front fork by pulling down while twisting it
A. Pull down by twisting.
B. Front Fork
A. Plastic Bag
B. Top Plug Wrench, 49 mm (Special Tool: 57001-1653)
C. Front Fork Top Plug
D. Outer Tube
E. Slide down
Place a drain pan under the front fork and drain fork oil.
NOTE
Pump the fork tube several times to discharge the fork oil.
A. Fork Oil
A. Plastic Bag
B. Front Fork Top Plug
C. Outer Tube
D. Top Plug Wrench, 49 mm (Special Tool: 57001-1653)
Protect the axle holder with a thick rag and secure it with a vise.
A. Axle Holder Part
B. Protect
C. Vise
WARNING
Clamping the axle holder too tight can damage it which will affect riding stability. Do not clamp the axle holder too tight.
NOTE
NOTE
When removing the adjuster assembly, do not force to loosen it at once using an impact wrench.
A. Adjuster Assembly
Compress the outer tube by hands and in stall the top plug wrench, 49 mm (special tool: 57001-1653) between the axle holder bottom and locknut.
WARNING
The fork spring applies pressure to the adjuster assembly and can eject the special tool with substantial force if the tool is not properly and securely placed. Be sure the tool is fully in place as shown in the photo, and keep fingers away to avoid getting them pinched between the tool, adjuster assembly and axle holder. Hold the locknut with a wrench and remove the adjuster assembly.
A. Top Plug Wrench, 49 mm (Special Tool: 57001-1653)
B. Axle Holder Bottom
C. Locknut
D. Wrench
E. Adjuster Assembly
Remove the push rod.
A. Push Rod
With the outer tube compressed by hand, remove the top plug wrench, 49 mm (special tool: 57001 -1653).
NOTICE
Removing the locknut and pushing the piston rod thread into the cylinder unit will damage the oil seal. Do not remove the locknut from the piston rod. Be careful of reaction force from the fork spring when removing the top plug wrench. Hold the cylinder unit tight enough so that the locknut does not damage the fork leg.
A. Top Plug Wrench, 49 mm (Special Tool: 57001-1653)
A. Plastic Bag
B. Front Fork Top Plug
C. Outer Tube
D. Top Plug Wrench, 49 mm (Special Tool: 57001-1653)
Remove the cylinder unit, collar and fork spring from the outer tube.
NOTICE
Disassembling the cylinder unit can lead to trouble. Do not disassemble the cylinder unit.
A. Cylinder Unit
B. Collar
C. Fork Spring
D. Outer Tube
E. Piston Rod
A. Plastic Bag
B. Top Plug Wrench, 49 mm (Special Tool: 57001-1653)
C. Cylinder Unit
D. Base Valve Assembly
E. Top Plug Wrench, 36 mm (Special Tool: 57001-1705)
Remove the base valve assembly from the cylinder unit.
A. Base Valve Assembly
B. Cylinder Unit
NOTE
Slowly compress the piston rod until it stops so that the base valve assembly can be removed easily.
NOTICE
Disassembling the base valve assembly can lead to trouble. Do not disassemble the base valve assembly.
Drain the fork oil from the cylinder unit by pumping the piston rod several times.
A. Fork Oil
B. Cylinder Unit
Hold the front fork at the inverted position for more than 20 minutes to allow the fork oil to fully drain. Clean the threads of cylinder unit and base valve assembly.
A. Threads
A. O-rings
With the piston rod fully compressed, pour the specified amount of fork oil.
NOTE
Put a hand over the two oil holes to prevent oil leak.
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