vernier caliper.
18 mm (0.71 in.) [C]

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

○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
Align
the
[A] of the top plug [B] with the grooves
• [C] of the stoppers
clamp [D], and loosen the fork spring compres-

•
•
•
•
•

sor nut.
Remove the fork spring compressor and clamps.
Raise the outer tube and screw the top plug into it.
Install the front fork (see Front Fork Installation).
Adjust the spring preload (see Spring Preload Adjustment).
Adjust the rebound damping force (see Rebound Damping Force Adjustment).

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

•
•
•
•

the top plug [A] with a wrench [B], loosen the
• Holding
piston rod rubber nut [C].

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

13-22 SUSPENSION
Front Fork
the fork piston rod stopper holder [A], remove the
• Using
piston rod assy stopper [B].
Special Tool - Fork Piston Rod Stopper Holder: 5700-1789

NOTE

○Install the fork piston rod stopper holder so that the long
side [C] faces upward.

• Remove:
Piston Rod Assy [A]
Fork Spring [B]
Spacer [C]

the fork oil into a suitable container [A].
•○Drain
Pump the outer tube up and down at least ten times to
expel the oil from the fork.

the spacer [A] with the flat surface [B] facing up• Install
ward.

the fork tube upright, press the outer tube [A].
• Hold
• 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. 440 mL (14.9 US oz.)
After disassembly and completely dry:
515 ±4 mL (17.4 ±0.14 US oz.)

SUSPENSION 13-23
Front Fork
the oil level as follows.
•○Measure
Hold the inner tube vertically in a vise.

○Move the inner tube up and down more than ten times in
order to expel all the air from the fork oil.

○Wait until the oil level settles.
○With the fork fully compressed, 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.
the holder bar [A] into the axle hole of the front fork
• Insert
[B].

○Position the bar left and right and evenly.

Special Tool - Fork Spring Compressor: 57001-1587

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

13-24 SUSPENSION
Front Fork
the adjust nut [A] onto the compression shaft as
• Screw
shown.

•
•

About 40 mm (1.6 in.) [B]
Screw the locknut [C].
Set the other side compression shaft same process.

the fork spring [A] with the smaller end [B] facing
• Install
upward.

• Install:
Piston Rod Assy [A]
•

Piston Rod Assy Stopper [B]
Screw the top plug [C].

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

the two bolts [B].
• Tighten
Install
the
holders [C] to the clamps as shown.
•
Special Tool - Fork Spring Compressor: 57001-1587

• Set the clamps [A] and compression shafts [B].

SUSPENSION 13-25
Front Fork
the nuts [A] onto the compression shafts [B] as
• Screw
shown.

•
•
•

About 15 mm (0.59 in.) [C]
Screw the piston rod assy stopper [D].
Remove the fork spring compressor from the front fork.
Remove the top plug.

the inner tube lower end in a vice.
• Hold
Using
fork piston rod stopper holder [A], tighten the
• piston the
rod assy stopper [B] securely.
Special Tool - Fork Piston Rod Stopper Holder: 5700-1789

NOTE

○Install the fork piston rod stopper holder so that the long
side [C] faces upward.

the O-ring [A] on the top plug [B] with a new one.
• Replace
Apply
grease
the new O-ring.
• Screw on the topiston
rod rubber nut [C] fully to the piston
• rod [D].

○Screw the piston rod rubber nut with the flat surface [E]

•

facing upward.
Screw in the top plug stopped onto the piston rod.

the top plug [A] with a wrench [B], tighten the
• Holding
piston rod rubber nut [C] against the top plug.

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

Torque - Piston Rod Rubber Nut: 15 N·m (1.5 kgf·m, 11 ft·lb)

the outer tube and screw the top plug into it.
• Rise
Install
the front fork (see Front Fork Installation).
•

Front Fork Disassembly

the front fork (see Front Fork Removal).
• Remove
Drain
the
fork oil (see Fork Oil Change).
•

13-26 SUSPENSION
Front Fork
Left Front Fork
Hold the inner tube lower end in a vise.
Screw the fork piston rod puller [A] onto the end of the
piston rod.

•
•

Special Tool - Fork Piston Rod Puller, M12 ×1.25 : 57001
-1289

the piston rod nut [B] until it touches the piston rod
• Screw
puller.
the piston rod nut with a wrench, remove the front
• Holding
fork bottom Allen bolt [C] and gasket.

the cylinder unit [A] from the inner tube.
•○Remove
Do not disassemble the cylinder unit.

the inner tube from the outer tube as follows.
•○Separate
Slide up the dust seal [A].

○Remove the retaining ring [B] from the outer tube.

○Holding the outer tube [A] by hand, pull the inner tube [B]
several times to pull out the outer tube.

SUSPENSION 13-27
Front Fork
the following parts from the inner tube.
• Remove
Inner Tube Guide Busing [A]
Outer Tube Guide Busing [B]
Washer [C]
Oil Seal [D]
Retaining Ring [E]
Dust Seal [F]

Front Fork Assembly

the following parts with new one.
• Replace
Oil Seal [A]

•

Outer Tube Guide Bushing [B]
Inner Tube Guide Bushing [C]
Dust Seal [D]
Retaining Ring [E]
Bottom Allen Bolt Gasket (Left Front Fork Only)
Install the following parts onto the inner tube.
Dust Seal
Retaining Ring
Oil Seal
Washer [F]
Outer Tube Guide Bushing
Inner Tube Guide Bushing

the inner tube to the outer tube.
• Insert
Fit
the
• tube. new outer tube guide bushing [A] into the outer

NOTE

○When assembling the new outer tube guide bushing,
hold the washer against the new outer tube guide bushing and tap the washer with the fork oil seal driver [B]
until it stops.
Special Tools - Fork Oil Seal Driver, 41: 57001-1288
or Fork Oil Seal Driver Weight, 26  46:
57001-1795
Fork Oil Seal Driver Attachment, 36  46:
57001-1798

• Install the oil seal by using the fork oil seal driver.
Special Tools - Fork Oil Seal Driver, 41: 57001-1288
or Fork Oil Seal Driver Weight, 26  46:
57001-1795
Fork Oil Seal Driver Attachment, 36  46:
57001-1798

• Install the retaining ring and dust seal into the outer tube.

13-28 SUSPENSION
Front Fork
Left Front Fork
Hold the inner tube lower end in a vise.
Insert the cylinder unit into the inner tube.
Screw the fork piston rod puller [A] onto the end of the
piston rod.

•
•
•

Special Tool - Fork Piston Rod Puller, M12 ×1.25 : 57001
-1289

the piston rod nut [B] until it touches the piston rod
• Screw
puller.
non-permanent locking agent to the threads of the
• Apply
front fork bottom Allen bolt [C].
the piston rod nut with a wrench, and tighten the
• Holding
front fork bottom Allen bolt.
Torque - Front Fork Bottom Allen Bolt: 23 N·m (2.3 kgf·m,
17 ft·lb)

• Pour in the specified type of oil (see Fork Oil Change).
Inner Tube, Outer Tube Inspection

inspect the inner tube [A].
• Visually
If there is any damage, replace the inner tube.

Since
damage to the inner tube damages the oil seal and dust
seal, replace the oil seal and dust seal whenever the inner
tube is replaced.

NOTICE
If the inner tube is badly bent or creased, replace
it. Excessive bending, followed by subsequent
straightening, can weaken the inner tube.
assemble the inner tube [A] and outer tube
• Temporarily
[B], and pump [C] them back and forth manually to check
for smooth operation.
If you feel binding or catching, the inner and outer tubes
must be replaced.

WARNING
A straightened inner or outer fork tube may fall in
use, possibly causing an accident resulting in serious injury or death. Replace a badly bent or damaged inner or outer tube and inspect the other tube
carefully before reusing it.

SUSPENSION 13-29
Front Fork
Dust Seal Inspection

the dust seal [A] for any signs of deterioration or
• Inspect
damage.
Replace it if necessary.

Spring Tension Inspection

a spring becomes shorter as it weakens, check its
• Since
free length [A] to determine its condition.
If the spring of either fork leg is shorter than the service
limit, it must be replaced. If the length of a replacement
spring and that of the remaining spring vary greatly, the
remaining spring should also be replaced in order to keep
the fork legs balanced for motorcycle stability.
Spring Free Length
Standard:
279.9 mm (11.02 in.)
Service Limit: 275 mm (10.8 in.)

13-30 SUSPENSION
Rear Shock Absorber
Rebound Damping Force Adjustment

adjust the rebound damping force, turn the rebound
• To
damping adjuster [A] to the desired position.

○The standard adjuster setting is the 1 1/4 turns out from
the fully clockwise position.
Rebound Damping Force Adjustment
Adjuster
Position

Damping
Force

Setting

Load

Road

Speed

1 4/5 turns
out

Weak

Soft

Light

Good

Low

↑

↑

↑

↑

↑

↑

↓

↓

↓

↓

↓

↓

0

Strong

Hard

Heavy

Bad

High

Spring Preload Adjustment

the rear shock absorber from the frame (see
• Remove
Rear Shock Absorber Removal).
the locknut and turn out the adjusting nut to free
• Loosen
the spring.
Special Tool - Hook Wrench T = 3.2 R37: 57001-1539

adjust the spring preload, turn in the adjusting nut [A]
• To
to the desired position and tighten the locknut [B].
Spring Length [C]
Spring Preload Setting
Standard:
Spring length 199.6 mm (7.86 in.)
Usable Range:

Spring length 190.5  200.5 mm (7.500
 7.894 in.)

Spring Adjustment
Adjuster
Position

Damping
Force

Setting

Load

Road

Speed

200.5 mm
(7.894 in.)

Weak

Soft

Light

Good

Low

↑

↑

↑

↑

↑

↑

↓

↓

↓

↓

↓

↓

190.5 mm
(7.500 in.)

Strong

Hard

Heavy

Bad

High

Rear Shock Absorber Removal

• Support the front of the motorcycle with the stand.
WARNING
When raising the rear wheel off the ground and removing part(s) from the motorcycle, be sure to support the front of the motorcycle, or the motorcycle
may fall over. It could cause an accident and injury.

SUSPENSION 13-31
Rear Shock Absorber

• Remove:
Right Frame Cover (see Frame Cover Removal in the
•

Frame chapter)
Loosen:
Upper Rear Shock Absorber Bolt [A] and Nut