ANUAL SERVICE M

INSPECTION

FORK CAP

Check the fork cap assembly for damage.

Check the bushing for excessive wear or scratches. Check the spring for fatigue or damage.

Check the compression adjuster for clicks.

Replace the fork cap as an assembly if necessary.

Apply fork oil to new O-rings and install them.

FORK CENTER BOLT

Check the fork center bolt for damage.

Check the adjuster rod for stepped wear or damage. Check the rebound adjuster for clicks.

Replace the fork center bolt as an assembly if neces­sary.

Apply fork oil to a new O-ring and install it.

SLIDER/OUTER TUBE

Check the outer tube and slider for score marks, scratches and excessive or abnormal wear.

Check the outer tube for damage or bend.

Set the slider on V-blocks and measure the runout.

Turn the slider and measure the runout using a dial 05 ~ shown indicator.

Actual runout is 1/2 of the total indicator reading.

SERVICE LIMIT: 0.20 mm (0.008 in)

Replace if the service limit is exceeded, or there are scratches or nicks that will allow fork oil to leak past the seals.

FORK SPRING

Measure the fork spring free length by placing it on a flat surface.

SERVICE LIMIT: 493 mm (19.4 in)

BUSHING/BACK-UP RING

Check the bushing for excessive wear or scratches. If copper appears on the surface, replace the bush­ing.

Replace the back-up ring if there is distortion at the points shown.

Remove any metal powder from the slider and guide bushings with a nylon brush and fork oil.

BACK-UP RING

FORK DAMPER

Check the fork damper for bends or damage.

Check the fork damper piston rod for bends, wear or damage.

Check the fork damper operation by pumping the piston rod.

If the operation is not smooth, fill the fork damper with fork oil and check the fork damper operation again (page 14-25).

SLIDER BUSHING

OUTER TUBE

GUIDE BUSHING

•a O-RINGS

FORK DAMPER

PUSH ROD

O-RING

/ DUST SEAL / 7

ф у/ j j / j J *ШШ BACK-UP RING

FORK SPRING WEAR STOPPER RING

Before assembly, wash all parts with a high flash­point or non-flammable solvent and wipe them dry.

OUTER TUBE AND SLIDER ASSEMBLY

Wrap the end of the slider with tape. m ічт тдрс

Coat new oil seal and dust seal lips with fork oil. / / "

Install the dust seal and stopper ring onto the slider.

Install the oil seal onto the slider with its marked

side facing the dust seal. 1

Remove the tape from the end of the slider.

Install the back-up ring, guide bushing and slider bushing.

NOTE:

Remove the burrs from the bushing mating surface, being careful not to peel off the coating.

Coat the slider and guide bushings with fork oil and install the slider into the outer tube.

TOOL:

Fork seal driver, 47 mm

Extend the fork damper piston rod to its maximum length.

Pour the recommended fork oil into the fork damper.

RECOMMENDED FORK OIL:

Pro Honda HP Fork Oil 5W or equivalent

STANDARD CAPACITY:

192 cm3 (6.5 US oz, 6.8 Imp oz)

Apply fork oil to the bushing and new О-rings on the

fork cap assembly. 4га

Extend the fork damper piston rod to maximum.

Hold the rod end, install the fork cap assembly into the fork damper.

If it is difficult to install the fork cap assembly, the fork damper oil level might be higher than standard.

Inspect the fork damper oil level again.

Set the fork damper in a vise with a piece of wood or soft jaws to avoid damage.

Tighten the fork cap assembly to the specified torque by holding the fork damper using the special tool.

TOOL:

Lock nut wrench, 50 mm 07WMA-KZ30100

TORQUE: 30 N m (3.1 kgf-m, 22 Ibf ft)

Hold the fork damper in an upright position and pump the fork piston rod 100 mm (3.9 in) slowly, several times.

Turn the lock nut clockwise until it is lightly seated.

NOTE:

• Set the rebound adjuster and compression adjuster counterclockwise to the softest position.

• Check the fork damper piston rod sliding surface for damage.

• Apply fork oil to the fork damper piston rod slid­ing surface.

Cover the piston rod end with a clean shop towel to prevent damage.

Blow out any extra oil in the fork damper spring chamber by fully stroking the fork damper piston rod.

Drain the extra oil from the oil hole (After '07: oil,

holes) of the fork damper. 05 ~ 07 shown: FORK DAMPER

Blow out any oil from the oil hole (After '07: holes) of the fork damper using compressed air.

Wipe off the oil completely from the fork damper.

oil

If you cannot use compressed air, remove the pres­sure release screw on the fork cap.

Hold the fork damper upside down for 10 minutes and drain the oil from the fork damper spring cham­ber.

Tighten the pressure release screw to the specified torque.

TORQUE: 1.2 N-m (0.1 kgf-m, 0.9 Ibf-ft)

FORK DAMPER OPERATION INSPECTION

• Turn the compression adjuster counterclockwise to the softest position.

• Check the fork damper piston rod sliding surface for damage.

• Apply fork oil to the fork damper piston rod slid­ing surface.

Inspect the fork damper operation after air bleeding (page 14-23).

Cover the piston rod end to prevent damage.

Fully stroke the fork damper piston rod by pushing down the fork damper.

Check the fork damper piston rod for smooth opera­tion.

If the fork damper piston rod operation is not smooth, check the piston rod for bends or damage.

Hold the fork damper level while the fork damper piston rod is fully extended and compressed by hand.

Release the fork damper piston rod then check that it extends to its maximum length.

If the fork damper piston rod does not extend to maximum, bleed the fork damper again.

Wipe the oil completely off from the fork damper. Compress the fork piston rod 200 - 250 mm (7.9 - 9.8 in) from fully extended and hold the fork damper in an upright position for 10 minutes.

There should be no oil leaking from the fork damper spring chamber and piston rod.

If oil leaks from the spring chamber or piston rod, replace the fork damper assembly.

Hold the fork damper on level ground and release the fork damper piston rod, then check that the pis­ton rod extends to its maximum length.

FORK DAMPER INSTALLATION/PREPARATION

If the outer tube and slider (fork) have not been dis­assembled, turn the fork upside down for 20 min­utes and drain the oil from the inside of the outer tube and slider completely (7 cc at 20°C/ 68°F).

Amount of fork oil left in the fork (without damper and spring)

If the fork damper has not been disassembled from the outer tube/slider, turn it upside down for 20 min­utes and drain the oil from the inside of the outer tube and slider completely (12 cc at 20°C/ 68°F).

Amount of fork oil left in the fork (within damper and spring)

Tighten the lock nut fully and measure the length as shown.

STANDARD: 11-13 mm (0.43 - 0.51 in)

Wipe the oil completely off the fork damper.