fully seated position, or the adjusting mechanism
may be damaged.

Front Fork Removal (Each Fork Leg)
Loosen the front fork top plug [A] beforehand if the fork
leg is to be disassembled.
○Place a plastic bag [B] over the top plug to protect the top
plug.
Special Tool - Top Plug Wrench (45 mm) [C]: 57001-1741

○Loosen

NOTE

the top plug after loosening the handlebar
clamp bolt [D] and upper front fork clamp bolt [E].

• Remove:
Upper Fairing Assembly (see Upper Fairing Assembly
Removal in the Frame chapter)
Front Wheel (see Front Wheel Removal in the
Wheels/Tires chapter)
Front Fender (see Front Fender Removal in the Frame
chapter)

13-12 SUSPENSION
Front Fork

• Loosen:
Handlebar Clamp Bolt [A]
Upper Front Fork Clamp Bolt [B]
Lower Front Fork Clamp Bolts [C]
○To prevent falling away, support the front fork when loosening the clamp bolts.
With a twisting motion, work the fork leg down and out.

•

Front Fork Installation (Each Fork Leg)

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

•

7 mm (0.28 in.) [B]
Steering Stem Head [C]
Tighten:
Torque - Front Fork Clamp Bolts (Lower): 23 N·m (2.3
kgf·m, 17 ft·lb)

NOTE

○Tighten the two lower front fork clamp bolts alternately
two times to ensure even tightening torque.
a plastic bag over the top plug to protect the plug.
• Place
Tighten:
•
Torque - Front Fork Top Plugs: 35 N·m (3.6 kgf·m, 26 ft·lb)

NOTE

○Tighten the front fork top plug before tightening the handlebar clamp bolt and upper front fork clamp bolt.
○The tightening torque reduces to 90% of the specified
value due to there is the distance between the octagonal hole [A] and the square hole [B].
○To obtain the correct tightening torque with your torque
wrench [C], install it to the special tool as shown.

• Tighten:
Torque - Front Fork Clamp Bolts (Upper): 20 N·m (2.0
kgf·m, 15 ft·lb)
Handlebar Clamp Bolts: 25 N·m (2.5 kgf·m, 18
ft·lb)

the removed parts (see appropriate chapters).
• Install
Check
that the rebound, compression and spring preload
• adjusters
on both sides are the same setting.

SUSPENSION 13-13
Front Fork
Front Fork Oil Change

the front fork (see Front Fork Removal (Each
• Remove
Fork Leg)).

NOTICE
Do not loosen the bolt [A]. The front fork could be
damaged.

the fork leg with a vise.
• Hold
Place
• plug. a plastic bag [A] over the top plug to protect the top
the wrench [B], unscrew the top plug [C] out of the
• Using
outer tube.
Special Tool - Top Plug Wrench (45 mm): 57001-1741

• 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, and then
tighten the two bolts [C].
Special Tool - Fork Spring Compressor: 57001-1540

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

13-14 SUSPENSION
Front Fork
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.
•

up the suitable jack until the piston rod nut [A] comes
• Lift
out.

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

the front fork from the fork spring compressor.
• Remove
• Remove:
Plastic Collar [A]
Collar [B]
Fork Spring [C]

SUSPENSION 13-15
Front Fork
the fork oil into a suitable container [A].
•○Drain
Pump the outer tube up and down at least 10 times to
expel the oil from the fork.

the fork tube upright, press the outer tube [A].
• Hold
Pour
• in the type and amount of fork oil specified.
Suspension Oil - SS47 (1L): 44091-0010
Amount (Per Side):
When changing oil:
Approx. 295 mL (10.0 US oz.)
After disassembly and completely dry:
345 ±2.5 mL (11.7 ±0.085 US oz.)

the outer tube up and down (about 20 mm (0.79
• Move
in.)) more than 10 times in order to expel the air from the
fork oil.
the oil level as follows.
•○Measure
Hold the inner tube vertically in a vise.

○Wait until the oil level settles.
○With the fork fully compressed, insert a tape measure or
rod into the inner tube [A], and measure the distance [B]
from the top [C] of the outer tube [D] to the oil.
Oil Level (fully compressed, without spring and collar)
Standard:
160 ±2 mm (6.3 ±0.08 US oz.)

NOTE

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

○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.

13-16 SUSPENSION
Front Fork

• Install:
Fork Spring [A]
Collar [B]
Plastic Collar [C]

• Install the clamps [A] as shown.
NOTE

○Set the clamps so that the cutout [B] do not fit the hole
[C] of the plastic collar [D], and then tighten the two bolts
[E].
Special Tool - Fork Spring Compressor: 57001-1540

the fork spring compressor [A], front fork [B], protector
• Set
and suitable jack.
Special Tool - Fork Spring Compressor: 57001-1771

• Lift up the suitable jack until the piston rod nut comes out.

the piston rod nut [A] onto the piton rod [B] as
• Screw
shown.
13 mm (0.51 in.) or more [C]

SUSPENSION 13-17
Front Fork
the O-ring [A] on the top plug [B] with 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.
Torque - Piston Rod Nut: 27 N·m (2.8 kgf·m, 20 ft·lb)

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

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, and then
tighten the two bolts [C].
Special Tools - Fork Spring Compressor: 57001-1540
Fork Spring Compressor: 57001-1587

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

13-18 SUSPENSION
Front Fork

• 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.

the adjust nut [A] onto the compression shaft as
• Screw
shown.

•
•

About 20 mm (0.79 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.

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

SUSPENSION 13-19
Front Fork
the fork spring compressor from the front fork.
• Remove
Remove:
• Plastic Collar [A]
Collar [B]
Fork Spring [C]

the fork oil into a suitable container [A].
•○Drain
Pump the outer tube up and down at least 10 times to
expel the oil from the fork.

the fork tube upright, press the outer tube [A].
• Hold
Pour
• in the type and amount of fork oil specified.
Suspension Oil - SS47 (1L): 44091-0010
Amount (Per Side):
When changing oil:
Approx. 295 mL (10.0 US oz.)
After disassembly and completely dry:
345 ±2.5 mL (11.7 ±0.085 US oz.)

the outer tube up and down (about 20 mm (0.79
• Move
in.)) more than 10 times in order to expel the air from the
fork oil.

13-20 SUSPENSION
Front Fork
the oil level as follows.
•○Measure
Hold the inner tube vertically in a vise.

○Wait until the oil level settles.
○With the fork fully compressed, insert a tape measure or
rod into the inner tube [A], and measure the distance [B]
from the top [C] of the outer tube [D] to the oil.
Oil Level (fully compressed, without spring and collar)
Standard:
160 ±2 mm (6.3 ±0.08 US oz.)

NOTE

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

○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.

• Install:
Fork Spring [A]
Collar [B]
Plastic Collar [C]

• Install the clamps [A] as shown.
NOTE

○Set the clamps so that the cutout [B] do not fit the hole
[C] of the plastic collar [D], and then tighten the two bolts
[E].
Special Tools - Fork Spring Compressor: 57001-1540
Fork Spring Compressor: 57001-1587

SUSPENSION 13-21
Front Fork
the holder bar [A] and compression shafts [B].
• Set
Screw
• comes inout.the fork compressor nuts until the piston rod nut

the piston rod nut [A] onto the piton rod [B] as
• Screw
shown.
13 mm (0.51 in.) or more [C]

the O-ring [A] on the top plug [B] with 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.
Torque - Piston Rod Nut: 27 N·m (2.8 kgf·m, 20 ft·lb)

the stoppers [A] of the top plug with the grooves [B]
• Align
of the clamp, and loosen the fork spring compressor nut.
the fork spring compressor and clamps.
• Remove
Raise
the
outer tube and screw the top plug into it.
• Install the front
fork (see Front Fork Installation (Each Fork
• Leg)).

Front Fork Disassembly

the front fork (see Front Fork Removal (Each
• Remove
Fork Leg)).
the fork oil (see Front Fork Oil Change).
• Drain
Take
the
seal [A] off the outer tube.
• Separatedust
the outer tube from the inner tube.
•

13-22 SUSPENSION
Front Fork

• Remove:
Retaining Ring [A]
Oil Seal [B]
Spacer [C]
If necessary, remove the guide bushing [D] as follows.

• Install the head pipe outer race remover [A].
Special Tool - Head Pipe Outer Race Remover ID > 37 mm:
57001-1107

a suitable arbor [A].
• Prepare
Length: About 500 mm (19.7 in.)
Diameter: About 30 mm (1.2 in.)
Insert the arbor.
Holding the outer tube [B], remove the guide bushing by
tapping the arbor.
○Take care not to scratch the inner wall of the outer tube.

•
•

Front Fork Assembly

installing the guide bushing [A], prepare a suitable
• When
spacer [B] in the same size as the spacer [C] of front fork.
Spacer – 44 × 54 × 2 mm (1.7 × 2.1 × 0.08 in.):
92026-0165

the spacers and the guide bushing to the inner tube
• Insert
[D], and insert the inner tube to the outer tube temporarily.

the fork oil seal driver attachment [A], and install
• Install
the guide bushing [B] with the fork oil seal driver weight
until it is bottomed.
Special Tools - Fork Oil Seal Driver Attachment, 36  46:
57001-1798
Fork Oil Seal Driver Weight, 26  46:
57001-1795

○When

NOTE

installing the guide bushing, the “fork oil seal
driver, 43” (57001-1530) cannot use.

out the inner tube and remove the special tools and
• Pull
added spacer.

SUSPENSION 13-23
Front Fork
the oil seal [A] and dust seal with new ones.
• Replace
Apply
teflon
grease to the oil seal lips.
• Place an oil containing
plastic bag [B] over the end of the
• inner tube andcoated
holes [C] to protect the oil seal and dust
seal [D].
○The inner tube hole has a sharp edge that cut out the
sealing lip of the seals as they are pushed down over the
inner tube.
Install the following parts onto the inner tube.
Dust Seal
Retaining Ring [E]
Oil Seal
Spacer [F]
Apply grease to the outer circumference of the oil seal.

•

•
the inner tube to the outer tube.
• Insert
Press
the oil seal by using the fork oil seal driver.
•

Special Tools - Fork Oil Seal Driver Weight, 26  46 [A]:
57001-1795
Fork Oil Seal Driver Attachment, 36  46
[B]: 57001-1798
or Fork Oil Seal Driver, 43: 57001-1530

the retaining ring and dust seal onto the outer tube.
• Install
Pour
in
• Change).the specified type of oil (see Front Fork Oil

Inner 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.

13-24 SUSPENSION
Front Fork
Dust Seal Inspection

the dust seals [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:
254.6 mm (10.02 in.)
Service Limit: 250 mm (9.84 in.)

Front Fork Scrapping

WARNING
Since the front fork contains nitrogen gas, do not incinerate the front fork without first releasing the gas
or it may explode. Before a front fork is scrapped,
drill a hole at the point [A] shown to release the nitrogen gas completely. Wear safety glasses when
drilling the hole, as the gas may blow out bits of
drilled metal when the hole opens.

SUSPENSION 13-25
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 2 1/4 turns out from
the fully clockwise position.
Rebound Damping Force Adjustment
Adjuster
Position

Damping
Force

Setting

Load

Road

Speed

4 turns out

Weak