Disassembling Front Fork

Prepare for disassembling by raising front end of motorcycle on stand or suitable support, so wheel is off the floor.

Remove front and side fork trim panel or headlamp

Remove front and side fork trim panel or headlamp

Figure 2F-6. Removing Fork Slider Bushing housing. Remove headlamp. Disconnect at terminal strip the two headlamp wires and all wires that pass through handlebars. Disconnect throttle and spark advance cables from carburetor and circuit breaker.

Remove front wheel as described in Section 2C. Remove front brake hand lever bracket and coil clip on fender. Turn off front axle sleeve nut and pivot stud nut, and pull brake side cover and shoe assembly and axle sleeve off fork. Remove front fender.. Slider bushing play can best be checked at this point. Remove the handlebars.


Remove the fork stem nut (1) and nut lock (1A) (if used). Remove the two upper bracket bolts (2) with oil seal (3) and upper bracket cover (4) (If used). Lift off handlebar and fork bracket (5). Remove head bearing nut (6). Remove upper head bearing (7) and pull fork out bottom of steering head.

Note: Frame head bearing Lock Nut Wrench, Part No. 96219-50, is used to remove nut (6).

Loosen fork bracket clamping studs (8) and slide fork bracket (9) off fork tubes with fork slider covers (10). Turn out two slider tube plugs (11) and invert sliders to drain out oil and remove fork springs (12).

Figure 2F-7. Driving in Fork Slider Bushing
Figure 2F-8. Reaming Replacement Bushing

Remove damper valve stud lock nut (13) from bottom of slider and pull slider tube (14) out of slider (24). Pinch out snap ring (15) from lower end of slider tube and drop out damper tube lower bushing (17). Discard gaskets (16 and 18). Slide out damper valve assembly (19). Snap out spring ring(20), washer (21), felt washer (22) and pry out oil seal (23).


Prepare for disassembly as described in paragraph above. Turn out steering damper adjusting screw (1) and lift out parts 2 through 9. Parts 5, 7 and 9 may be loosened by inserting a screwdriver tip between parts and prying upward.

Turn off stem nut (10). Remove upper bracket bolts and washers (11) and lift off bracket cover (12) and upper bracket (13). Remove head bearing nut (14). Lift out upper head bearing (15) and slip fork assembly out of frame steering head.

NOTE: Frame head bearing Lock Nut Wrench, Part No. 96219-50, is used to remove nuts (10) and (14).

Remove slider tube plugs (16) and loosen clamping studs (17). Slip fork tube and slider assembly (22) out of bracket (21). Slider tube and slider disassembly is the same as described for non-adjustable fork.

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