Inspection

Fork spring

Measure the fork spring free length.

SERVICE LIMiT:

Replace the spring if it is shorter than the service limit.

fork tube/slider/piston

Check the fork tube, fork slider and piston for score marks, excessive or abnormal wear.

Replace any components which are worn or damaged.

Check the fork piston, ding for wear or damage. Check the rebound spring for fatigue or damage.

'3! PISfON

¡m REBOUND SPRiNG

Set the fork tube ir> V blocks and read the runout. Use 1 !2 the total Indicator reading to determine the actual runout.

Fork tube bushing

Visually inspect the slider and fork to be bushings. Replace the bushings if there is excessive scoring or scratching, or if the teflon is worn so that the copper surface appears on more than 3/4 of the entire surface.

Check the back-up ring; replace it if there is any distortion at: the points shown.

(IS BUSHIMG

(IS BUSHIMG

(4} COPPER SURFACES

(3) CHECK POINTS

(3) CHECK POINTS

(4} COPPER SURFACES

ASSEMBLY

Before assembly, wash all parts with a high flash point or nonflammable solvent and wipe them off completely.

(1) FORK TUBE CAP

(19) SPRING SEAT (18} FORK SPRING (1 7) PISTON RING (16! PISTON

11 5) REBOUNtiSPRIhlG

(1) FORK TUBE CAP

17) FORK SLIDER

STOPPER RING ¡¡¡^- (4) OIL SEAL î^-<5) BACK-UP RING / 7 16} SLIDER BUSHING/ / /

10) DRAIN BOLT

(14) FORK TUBE

(13) FORK TUBE BUSHING

11>OILLOCKPIECE (K)sbCKETBOLT

17) FORK SLIDER

(8) FORK LEG

instali the rebound spring into the fork tube. '87 '90 only:

install a new stopper ring onto the piston groove.

Place the oil lock piece on the end of the piston and insert the fork tube into the slider.

(2) PISTON

I) STOPPER RING

Piace the fork slider in a vise with soft jaws or use a shop towel. Apply a locking agent to the socket bolt and thread it into the piston. Tighten with a 6 mm hex wrench.

if) FORK SLIDER

NOTE

Temporarily Install the fork spring and fork cap bolt to tighten the socket bolt.

Place the slider bushing over the fork tube and rest it on the slider.

Drive the boshing into piace with the seal driver and remove the old bushing or equivalent tool.

Coat a new oil seal with suspension fluid and install it with the seal markings facing up. Drive the seal in with the sea! driver.

TOOLS:

Fork seal driver: Attachment:

07347 — KA50100 07947-KF00100

i f ) FORK SEAL DRIVER i

(31 FORK SLIDER

install the stopper ring into the gtoove in the fork slider, Install the dust seal surely.

(1) STOPPER RING

(2}F0RKSLIDE

11} SPECIFIED: LEVEL

(3! SPACER

(2) WASHER

11} SPECIFIED: LEVEL

Com press the fork leg and pour suspension huld into the fork tube.

SPECIFIED LEVEL:

install the fork spring, washer and spacer into the fork tube. NOTE

■ Note the spring direction: the tapered end must face toward the bottom,

Loose!1,' install the fork tube cap with a new Going,

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