2.17FRONT FORK
REMOVAL
1. Support motorcycle so front end is off floor and forks are
fully extended. Remove brake caliper and front wheel. See
2.3 FRONT WHEEL.
2. Remove front fender. See 2.27 FRONT FENDER.
3. Loosen screws. Do not remove tube caps. Slide fork sides
downward clear of fork brackets.
4. Repeat procedure for opposite fork tube and slider
assembly.
DISASSEMBLY
TOOL NAMEPART NUMBER
FORK HOLDING TOOLHD-41177
1. See Figure 2-82. Clamp fork tube and slider assembly in
FORK HOLDING TOOL (Part No. HD-41177) and mount
in vise.
NOTE
In next step, use a 12mm allen wrench to loosen seat pipe
screw.
2. See Figure 2-84.While internal components are still under
tension and less prone to rotate, break loose but do not
completely unthread seat pipe screw.
NOTE
On right fork tube and slider assembly, remove axle holder to
access seat pipe screw.
Wear safety glasses or goggles when servicing fork
assembly. Do not remove slider tube caps without relieving
spring preload or caps and springs can fly out, which could
result in death or serious injury. (00297a)
3. See Figure 2-85. Remove fork tube cap (7) and O-ring
(6).
4. Remove the long spring collar (8).
5. Remove from fork holding tool and invert fork over a suit-
able container. Allow fork to drain. Extend and retract slider
several times to push oil out of internal components.The
washer (5), and spring (4) will fall out of fork tube.
6. Clamp fork tube in holder. Mount fork holding tool horizont-
ally in vise.
7. See Figure 2-83. Remove slider cover from slider by
inserting brass drift into notch in slider and lightly tapping
cover.
8. See Figure 2-85. Compress oil seal retaining ring (11) and
remove retaining ring from groove in top of slider bore.
9. Remove seat pipe screw (20) and washer (19) from bottom
of slider (16, 17). Retain the seat pipe screw and washer.
10. Withdraw slider from fork tube (1) until bushing guide (14)
contacts bushing (24) on fork tube. Bushing guide is a
slight interference fit in slider.
11. Using the slider as a slide hammer, hit the bushing with
the bushing guide with a quick continuous stroke until
slider is pulled free of the fork tube.
12. Drain the slider and allow the stop oil lock piece (15) to
fall free.
NOTE
If replacing the slider only, the components remaining in the
fork tube can be left assembled and the fork re-assembled.
See 2.17 FRONT FORK, Assembly.
13. If still attached to seat pipe, remove stop oil lock piece
from the lower end of seat pipe.
14. Remove seat pipe (3) piston and ring assembly.
15. Remove rebound spring (2).
16. Remove oil seal (12), seal spacer (13), and bushing guide
(14).
17. Repeat procedure for opposite fork tube and slider
assembly.
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