Setting

Load

Road

Speed

12

Weak

Soft

Light

Good

Low

↑

↑

↑

↑

↑

↑

↓

↓

↓

↓

↓

↓

0

Strong

Hard

Heavy

Bad

High

Spring Preload Adjustment (Left Front Fork Only)

adjust the spring preload, turn the spring preload ad• To
juster [A].

○The standard adjuster setting is the 8 turns in from the
fully counterclockwise position.

○The spring preload can be left soft for average riding. But
it should be adjusted harder for high speed riding or riding
with a passenger. If the spring action feels too soft or too
stiff, adjust it in accordance with the following table.
Spring Action
Adjuster
Position

Damping
Force

Setting

Load

Road

Speed

0

Weak

Soft

Light

Good

Low

↑

↑

↑

↑

↑

↑

↓

↓

↓

↓

↓

↓

30 turns in

Strong

Hard

Heavy

Bad

High

13-10 SUSPENSION
Front Fork
Front Fork Removal (Each Fork Leg)

• Remove:
Front Fender (see Front Fender Removal in the Frame
chapter)
Front Wheel (see Front Wheel Removal in the
Wheels/Tires chapter)
Loosen the upper front fork clamp bolt [A] and fork top
plug [B] beforehand if the fork leg is to be disassembled.
○Place a plastic bag over the top plug to protect the top
plug.

NOTE

○Loosen the front fork top plug after loosening the upper
front fork clamp bolt.
the upper front fork clamp bolt and lower front fork
• Loosen
clamp bolts [C].
• With a twisting motion, work the fork leg down and out.

Front Fork Installation

the fork so that the top plug end [A] of the outer
• Install
tube as shown.

•
•

6 mm (0.24 in.) [B]
Steering Stem Head [C]
Place a plastic bag over the top plug to protect the top
plug.
Tighten:
Torque - Lower Front Fork Clamp Bolts: 20.5 N·m (2.09
kgf·m, 15.1 ft·lb)
Front Fork Top Plugs: 22.5 N·m (2.29 kgf·m, 16.6
ft·lb)
Upper Front Fork Clamp Bolts: 20 N·m (2.0 kgf·m,
15 ft·lb)

NOTE

○Tighten the two lower front fork clamp bolts alternately
two times to ensure even tightening torque.

○Tighten the top plug before tightening the upper front
fork clamp bolt.
the removed parts (see appropriate chapters).
• Install
Adjust:
• Spring Preload (see Spring Preload Adjustment)
Rebound Damping Force (see Rebound Damping Force
Adjustment)

Front Fork Oil Change
Left Front Fork
Remove the front fork (see Front Fork Removal).
Hold the inner tube lower end in a vise.
Place a plastic bag over the top plug to protect the top
plug.
Unscrew the top plug [A] out of the outer tube.

•
•
•
•

SUSPENSION 13-11
Front Fork

• Install the clamps [A] as shown.
NOTE

○Set the clamps so that the cutout [B] of the upper side
does not touch the tongue shape of stopper, pull up the
outer tube [C] to hold it by the clamps, and then tighten
the two bolts [D]. The outer tube is used as a guide.
Special Tool - Fork Spring Compressor: 57001-1540

the fork spring compressor [A] and a suitable jack [B]
• Set
as shown.
Special Tool - Fork Spring Compressor: 57001-1771

the projection of the protector [A] into the front fork
• Insert
bottom hole [B].

the front fork [A] under the holder [B].
• Set
• Lift up the suitable jack, and hold the front fork.

13-12 SUSPENSION
Front Fork
up the suitable jack until the piston rod nut [A] comes
• Lift
out.
the fork spring stopper [B] between the piston rod
• Insert
nut and the holder [C] while holding up the top plug [D].
Special Tool - Fork Spring Stopper: 57001-1374

the piston rod nut with a wrench [A], remove the
• Holding
top plug [B] from the piston rod.

○Place a plastic bag over the top plug to protect the top
plug.

the front fork from the fork spring compressor.
• Remove
Remove:
• Washer [A]
Collar [B]
Rebound Damping Adjuster Rod [C]
Fork Spring [D]

the rod nut [A] onto the piston rod [B] as shown.
• Screw
14 mm (0.55 in.) or more [C]

the fork oil into a suitable container.
•○Drain
Using the piston rod puller [A], pump the piston rod [B] up
and down at least ten times to expel the oil from the fork.
Special Tool - Fork Piston Rod Puller, M12 × 1.25: 57001
-1289

SUSPENSION 13-13
Front Fork
the fork tube upright, press the outer tube [A] and
• Hold
the piston rod all the way down.
• Pour in the type and amount of fork oil specified.
Suspension Oil - KHL15-10 (1 L): 44091-0004
KHL15-10 (4 L): 44091-0013
Amount:
When changing oil: Approx. 370 mL (12.5 US oz.)
After disassembly and completely dry:
434 ±4 mL (14.7 ±0.14 US oz.)

the oil level as follows.
•○Measure
Hold the inner tube vertically in a vise.

○Using the piston rod puller [A], move the piston rod [B] up
and down more than ten times in order to expel all the air
from the fork oil.
Special Tool - Fork Piston Rod Puller, M12 × 1.25: 57001
-1289

○Remove the piston rod puller.
○Wait until the oil level settles.
○With the fork fully compressed and the piston rod fully

pushed in, insert a tape measure or rod into the inner
tube, and measure the distance from the top of the outer
tube to the oil.
Oil Level (fully compressed, without spring)
Standard:
99 ±2 mm (3.9 ±0.08 in.) (from the top
of the outer tube)

NOTE

○Fork oil level may also be measured using the fork oil
level gauge.
Special Tool - Fork Oil Level Gauge [A]: 57001-1290

○With the fork fully compressed and without fork spring,
insert the gauge tube into the inner tube [B] and position
the stopper across the top end [C] of the outer tube [D].
○Set the gauge stopper [E] so that its lower side shows the
oil level distance specified [F].
○Pull the handle slowly to pump out the excess oil until the
oil no longer comes out.
If no oil is pumped out, there is insufficient oil in the inner
tube. Pour in enough oil, then pump out the excess oil as
shown above.

13-14 SUSPENSION
Front Fork
the fork piston rod puller onto the end of the piston
• Screw
rod.
Special Tool - Fork Piston Rod Puller, M12 × 1.25: 57001
-1289

the puller up above the outer tube top.
• Pull
Install
• upward.the fork spring [A] with the smaller end [B] facing

the collar [A] so that the cut side [B] faces down• Install
ward.
• Install the washer [C] on the collar.

• Install the clamps [A] as shown.
Special Tool - Fork Spring Compressor: 57001-1540

NOTE

○Set the clamps so that the cutouts [B] do not fit the hole
[C] of the washer [D], pull up the outer tube [E] to hold
it by the clamps, and then tighten the two bolts [F]. The
outer tube is used as a guide.

the fork spring compressor [A], front fork [B], protector
• Set
and suitable jack.
• Lift up the suitable jack until the piston rod nut comes out.
Special Tool - Fork Spring Compressor: 57001-1771

SUSPENSION 13-15
Front Fork
up the fork piston rod puller.
• Hold
Insert
fork spring stopper [A] between the piston rod
• nut [B]the
and the holder [C] while holding up the fork piston
rod puller [D].
Special Tool - Fork Spring Stopper: 57001-1374

• Remove the fork piston rod puller.
• Install the rebound damping adjuster rod [A].

the distance between the bottom end [A] of the
• Check
top plug and rebound damping adjuster [B] with a pair of
vernier caliper.
18 mm (0.71 in.) [C]

the O-ring [A] on the top plug [B] with a new one.
• Replace
grease to the new O-ring.
• Apply
Install
on the piston rod, and screw it.
• Holdingthethetoptopplug
plug
a wrench, tighten the piston rod
• nut [C] against the topwithplug.

○Place a plastic bag over the top plug to protect the top
plug.
Torque - Piston Rod Nuts: 15 N·m (1.5 kgf·m, 11 ft·lb)

the fork spring stopper.
• Remove
the stoppers [A] of the top plug [B] with the grooves
• Align
[C] of the clamp [D], and down the suitable jack.
the front fork from the fork spring compressor.
• Remove
Raise
the
tube and screw the top plug into it.
• Install the outer
fork (see Front Fork Installation).
• Adjust thefront
spring
preload (see Spring Preload Adjust• ment).
the rebound damping force (see Rebound Damp• Adjust
ing Force Adjustment).

13-16 SUSPENSION
Front Fork
If using the spring compressor (57001-1587).
Install the clamps [A] as shown.

•

NOTE

○Set the clamps so that the cutout [B] of the upper side
does not touch the tongue shape of stopper, pull up the
outer tube [C] to hold it by the clamps, and then tighten
the two bolts [D]. The outer tube is used as a guide.
Special Tools - Fork Spring Compressor: 57001-1540
Fork Spring Compressor: 57001-1587

• Install the holders [E] to the clamps as shown.

the holder bar [A] into the axle hole of the front fork
• Insert
[B].

○Position the bar left and right and evenly.

Special Tool - Bar: 57001-1751 (For Left Fork Leg)

• Insert the compression shaft [A] and install the nut [B].

the lower end of the compression shaft [A] into the
• Insert
hole [B] of the holder bar.

SUSPENSION 13-17
Front Fork
the adjust nut [A] onto the compression shaft as
• Screw
shown.

•
•

About 30 mm (1.2 in.) [B]
Screw the locknut [C].
Set the other side compression shaft same process.

in the nuts [A] until the piston rod nut [B] comes
• Screw
out.

○Hold up the top plug [C] while screwing in the nut.

the fork spring stopper [A] between the piston rod
• Insert
nut [B] and the clamp [C] while holding up the top plug [D].
Special Tool - Fork Spring Stopper: 57001-1374

the piston rod nut with a wrench [A], remove the
• Holding
top plug [B] from the piston rod.

○Place a plastic bag over the top plug to protect the top
plug.

the fork spring compressor from the front fork.
• Remove
• Remove:
Washer [A]
Collar [B]
Rebound Damping Adjuster Rod [C]
Fork Spring [D]

13-18 SUSPENSION
Front Fork
the rod nut [A] onto the piston rod [B] as shown.
• Screw
14 mm (0.55 in.) or more [C]

the fork oil into a suitable container.
•○Drain
Using the piston rod puller [A], pump the piston rod [B] up
and down at least ten times to expel the oil from the fork.
Special Tool - Fork Piston Rod Puller, M12 × 1.25: 57001
-1289

the fork tube upright, press the inner tube [A] and
• Hold
the piston rod all the way down.
• Pour in the type and amount of fork oil specified.
Suspension Oil - KHL15-10 (1 L): 44091-0004
KHL15-10 (4 L): 44091-0013
Amount:
When changing oil: Approx. 370 mL (12.7 US oz.)
After disassembly and completely dry:
434 ±4 mL (14.7 ±0.14 US oz.)

If necessary, measure the oil level as follows.

○Hold the inner tube vertically in a vise.
○Using the piston rod puller [A], move the piston rod [B] up
and down more than ten times in order to expel all the air
from the fork oil.
Special Tool - Fork Piston Rod Puller, M12 × 1.25: 57001
-1289

○Remove the piston rod puller.
○Wait until the oil level settles.
○With the fork fully compressed and the piston rod fully

pushed in, insert a tape measure or rod into the inner
tube, and measure the distance from the top of the outer
tube to the oil.

SUSPENSION 13-19
Front Fork
Oil Level (fully compressed, without spring)
Standard:
99 ±2 mm (3.9 ±0.08 in.) (from the top
of the outer tube)

NOTE

○Fork oil lever may also be measured using the fork oil
level gauge.
Special Tool - Fork Oil Level Gauge [A]: 57001-1290

○With the fork fully compressed and without fork spring,
insert the gauge tube into the inner tube [B] and position
the stopper across the top end [C] of the outer tube [D].
○Set the gauge stopper [E] so that its lower side shows the
oil level distance specified [F].
○Pull the handle slowly to pump out the excess oil until the
oil no longer comes out.
If no oil is pumped out, there is insufficient oil in the inner
tube. Pour in enough oil, then pump out the excess oil as
shown above.

the fork piston rod puller onto the end of the piston
• Screw
rod.
Special Tool - Fork Piston Rod Puller, M12 × 1.25: 57001
-1289

the puller up above the outer tube top.
• Pull
the fork spring [A] with the smaller end [B] facing
• Install
upward.

the collar [A] so that the cut side [B] faces down• Install
ward.
• Install the washer [C] on the collar.

13-20 SUSPENSION
Front Fork

• Install the clamps [A] as shown.
Special Tools - Fork Spring Compressor: 57001-1540
Fork Spring Compressor: 57001-1587

NOTE

○Set the clamps so that the cutouts [B] do not fit the hole
[C] of the washer [D], pull up the outer tube [E] to hold
it by the clamps, and then tighten the two bolts [F]. The
outer tube is used as a guide.

• Set the holder bar [A] and compression shafts [B].
Special Tool - Bar: 57001-1751 (For Left Fork Leg)

in the fork compressor nut come out the piston rod
• Screw
nut.

○Hold up the fork piston rod puller while screwing in the
nut.

the fork spring stopper [A] between the piston rod
• Insert
nut [B] and the clamp [C] while holding up the fork piston
rod puller [D].
Special Tool - Fork Spring Stopper: 57001-1374

• Remove the fork piston rod puller.

• Install the rebound damping adjuster rod [A].

SUSPENSION 13-21
Front Fork
the distance between the bottom end [A] of the
• Check
top plug and rebound damping adjuster [B] with a pair of