NOTICE
Sticking muds or dusts on the sliding surface of the front fork could damage the oil seal, leading to an oil leak. Clean the sliding sur face after each ride.
A. Inner Tubes
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 five adjustments you can make to the front fork.
Air Pressure Adjustment
Air pressure acts as a progressive spring over the entire fork travel range. Since the air pressure in the fork legs increases with normal use, the fork action on your KX will get stiffer as the race progresses.
Therefore, it is not recommended to increase the air pressure for additional springing. The KX forks aredesigned to function without added air.
Compression Damping Adjustment
This adjustment affects how quickly the fork compresses. The fork compression damping adjuster has at least 20 positions. The fully seated position (adjuster turned fully clockwise) is the hardest set ting. Turning the adjuster counterclockwise 10 clicks from the fully seated position is the standard setting, turning it counterclockwise 20 or more clicks is the softest setting.
Fork Oil Level Adjustment
The fork oil level affects only the final 100 mm (4 in.) of fork travel. A higher oil level will make the fork rebound more quickly. A lower oil level will make the fork rebound more slowly.Optional Fork Springs Optional springs, softer and stiffer than standard, are available.
Fork Height
Steering is greatly affected by the fork height (how much the outer fork tubes protrude above the up-per fork clamp). The less the fork tube protrudes, the lighter the front end becomes and the greater the tendency for understeering and washout due to weight biasing. Increasing the amount of fork tube protrusion has opposite effects. Be sure that the front tire does not touch the fender when the fork
is fully compressed. Make this adjustment in 10 mm(0.39 in.) steps.
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/cm2, 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 air pressure relief screw located in front fork top plug. Make sure the front forks are fully extended with the front wheel off the ground when releasing the pressure.
Tightening Torque
Air Pressure Relief Screws: 1.3 Nm (0.13 kgfm, 12 in-b)
A. Air Pressure Relief Screw
B. Front Fork Top Plug
Compression Damping Adjustment
A. Cap (Both Sides)
To adjust the compression damping, turn the adjuster on the compression valve assembly with a standard tip screwdriver. Adjust the compression damping to suit your preference under certain con- ditions
NOTICE
Do not force the compression damping adjuster beyond the fully seated position, or the adjusting mechanism may be damaged.
Compression Damper Settings
A. Seated Position (Adjuster Turned Fully Clockwise)
B. Softer (Counterclockwise)
C. Harder (Clockwise)
D. Standard Setting
Number of turns counterclockwise usable range 20 clicks or more.
Standard Compression Damper Setting
10 clicks Counterclockwise from the fully seated position
NOTICE
The right and left fork tubes must be adjusted evenly. Install the caps on the bottom of the fork tubes.
Fork Oil Level Adjustment
Thoroughly clean the forks 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.
NOTE
A. Bolts
B. Front Fender
NOTE
Do not take off the compression valve assembly.
A. Front Fork Clamp Bolt (Upper)
B. Front Fork Top Plug
A. Bolts
B. Brake Hose Clamps
C. Bolts (Both Sides)
D. Front Fork Protectors
Loosen the front fork top plugs, and take the top plugs with the push rods off.
WARNING
The top plugs are under extreme spring pressure and may eject with great force during service. Use care when removing the top plugs. Wear eye and face protection.
A. Inner Tube (Stepped Portion)
B. Dust Seal
C. Outer Tube
Place a stand or other suitable support under the front wheel.
A. Suitable Support
B. Front Wheel
A. Front Fork Push Rod Nut
B. Wrench
C. Front Fork Top Plug
D. Fork Spring Seat
E. Fork Spring
Recommended Fork Oil _
KHL15-10 (1 L): P/No. 44091-0004 Install a push rod puller (special tool: 57001-1298) onto the push rod.
A. Push Rod Puller (Special Tool: 57001-1298)
B. Push Rod
Standard Fork Oil Level
95 +2 mm (3.74 0.08 in.)
Adjustable Range
75 115 mm (2.95 – 4.53 in.)
Remove the excess oil through the outer tube opening, using an oil level gauge (special tool: 57001-1290).
A. Outer Tube Opening
B. Oil Level Gauge (Special Tool: 57001-1290)
A. Push Rod Puller (Special Tool: 57001-1298)
B. Fork Spring
C. Fork Spring Seat
D. O-ring
A. Front Fork Push Rod Nut
B. Front Fork Top Plug
C. Push Rod
D. Wrench
Tightening Torque
Front Fork Push Rod Nuts: 15 N m (1.5 kgfm, 11 ft:lb)
Tightening Torque
Front Fork Top Plugs 28 N-m (2.9 kgfm, 21 ft:lb)
Tightening Torque
Front Fork Clamp Bolts (Upper): 20 N m (2.0 kgfm, 15 ft:lb)
Optional Fork Springs
Various fork springs are available to achieve suit- able front fork action in accordance with the rider’s weight and track condition. Harder springs stiffen the fork action and acceler- ate the rebound damping. Softer springs soften the fork action and slow down the rebound damping.
Fork Height Adjustment
Steering is greatly affected by the fork height. The less the fork height, the lighter the front end becomes and the greater the tendency for understeering and washout due to weight biasing. Increasing the fork height has opposite effects. Be sure that the front tire does not touch the fender when the fork is fully compressed. Make this adjustment in 10 mm steps.
NOTICE
Both fork heights should be adjusted evenly.
A. Fork Height
Standard Fork Height
18 mm (0.71 in.)
Between the top end of the outer tube and upper surface of the steering stem head.
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