FORK DAMPER INSTALLATION
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'05-'07 shown: FORK DAMPER ASSEMBLY
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Wipe the oil completely off the fork spring.
Install the fork spring into the fork assembly. Temporarily install the fork damper assembly into the fork assembly.
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Measure the combined length of the lock nut and piston rod end again. STANDARD: 11 - 13 mm (0.43 - 0.51 in) Install the push rod into the piston rod until it stops. Apply fork oil to new O-ring and install it. Install the fork center bolt to the fork damper piston rod by aligning the flat-side of the center bolt adjusting rod with the flat-side of the push rod. Tighten the center bolt fully by hand. |
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Set the axle holder of the slider in a vise with a piece of wood or soft jaws to avoid damage. Push the fork damper out of the lock nut from slider, while install the piston base or mechanic's stopper tool between the axle holder and lock nut. TOOL: Piston base 07958-2500001 or Fork rod stopper 07AMB-KZ3A100 (U. S.A. only) |
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Measure the length of the lock nut and center bolt clearance. STANDARD: 1.5 - 2.0 mm (0.06 - 0.08 in) If the clearance is out of specification, check the lock nut and center bolt installation. |
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Tighten the lock nut to the center bolt by hand until they touch. Tighten the lock nut to the specified torque. TORQUE: 22 N m (2.2 kgf m, 16 Ibf ft) |
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Do not over-tighten the vise on the axle holder. |
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LOCK NUT |
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PISTON BASE |
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CENTER BOLT |
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flfYr |
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ЦШI O-RING |
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Check the push rod installation by turning the push rod right and left. |
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LOCK NUT |
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CENTER BOLT |
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Be careful not to damage the lock nut and fork center bolt hole. |
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AXLE HOLDER |
Remove the piston base or mechanic's stopper tool between the axle holder and lock nut while pushing the fork damper.
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LOCK NUT |
PISTON BASE
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CENTER BOLT |
Install the fork center bolt into the axle holder and tighten it to the specified torque.
TORQUE: 69 Nm (7.0 kgf m, 51 Ibf ft)
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Measure the length between the axle holder and outer tube.
Compare the length at assembly and disassembly; they should be same length.
STANDARD: 317 ± 2 mm (12.5 ± 0.08 in)
If the length at assembly is longer than at disassembly, check the center bolt and lock nut installation.
OIL CAPACITY ADJUSTMENT
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Remove the fork damper assembly from the outer tube.
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Be sure the oil capacity is the same in both fork legs. |
Pour the recommended fork oil into the fork leg.
RECOMMENDED OIL:
Pro Honda HP Fork Oil 5W or equivalent
STANDARD OIL CAPACITY:
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05 - '07: 332 cm1 (11.2 oz, 11.7 Imp oz) After '07: 324 cm3 (11.0 US oz, 11.4 Imp oz)
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Maximum oil capacity |
402 cm3 (13.6 US oz, 14.2 Imp oz) |
Slightly stiffer near full compression. |
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Minimum oil capacity |
306 cm3 (10.3 US oz, 10.8 Imp oz) |
Slightly softer near full compression. |
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damper assembly into the outer tube. |
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BOTTOM BRIDGE PINCH BOLTS |
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LOCK NUT WRENCH |
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Refer to torque wrench reading information, on Ipage 14-5) service information. |
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07WMA-KZ30100 |
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INSTALLATION Install the fork leg and tighten the fork bottom bridge pinch bolts to the specified torque. TORQUE: 20 N m (2.0 kgf m, 15 Ibf ft) |
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Tighten the fork damper to the specified torque using the special tool. |
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TORQUE: Actual: 34 N m (3.5 kgf m, 25 Ibf-ft) Indicated: 31 N-m (3.2 kgf m, 23 Ibf-ft) |
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TOOL: Lock nut wrench, 50 mm |
STANDARD POSITION
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PRESSURE RELEASE SCREW |
Loosen the bottom bridge pinch bolts.
For ease when releasing the air pressure after the forks are installed, position the fork outer tubes so the pressure release screws are in front of the compression adjusters.
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BOTTOM BRIDGE PINCH BOLTS |
Align the top surface of the top bridge with the outer tube upper surface as shown.
Tighten the fork bottom bridge pinch bolts to the specified torque.
TORQUE: 20 N m (2.0 kgf m, 15 Ibf ft)
Tighten the fork top bridge pinch bolts to the specified torque.
TORQUE: 22 N m (2.2 kgf m, 16 Ibf ft)
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TOP BRIDGE PINCH BOLTS |
Over-tightening the pinch bolts can deform the outer tube. A deformed outer tube must be replaced.
Inspect the wear rings for wear or damage. Replace the wear ring, if it is 1.5 mm (0.06 ii with the outer tube.
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WEAR RINGS |
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Make sure the wear rings with their end gaps facing rearward.
Clean and apply locking agent to the fork protector mounting bolt threads.
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SCREWS/CLAMP |
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FORK PROTECTOR |
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BOLTS/ CLAMP I |
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CALIPER * MOUNTING BOLTS |
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Install the fork protector and tighten the mounting bolts to the specified torque.
TORQUE: 7 N m (0.7 kgf m, 5.2 lbf-ft)
Clean and apply locking agent to the front brake caliper mounting bolt threads.
Install the front brake caliper and tighten the mounting bolts to the specified torque.
TORQUE: 30 Nm (3.1 kgf m, 22 Ibf ft)
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BOLTS |
Install the tripmeter cable clamp and screws. Tighten the tripmeter cable clamp screws to the specified torque.
TORQUE: 0.7 N-m (0.1 kgf m, 0.5 Ibf ft)
Install the brake hose clamp and bolts.
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COMPRESSION ADJUSTER |
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REBOUND ADJUSTER |
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Return the rebound adjuster and compression adjuster to the original positions as noted during removal.
After‘07: Install the steering damper (page 14-38) if it was removed.
Install the following:
- Front visor ('05 - '07: page 3-5, After '07: page 36)
- Front wheel (page 14-12)
