Assembling The Front Fork Legs
Fragment manuala — str. 265–267
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FRONT FORK
• Before assembling the front fork leg, make
Fork spring free length sure all of the components are clean.
262.0 mm (10.31 in)
Limit 1. Install:
257.0 mm (10.12 in) • Inner tube bushing “1” New
• Oil flow stopper “2”
• Spring
• Damper rod assembly “3”
EC3P61028
CAUTION:
Allow the damper rod assembly to slide
slowly down the inner tube “4” until it pro-
trudes from the bottom of the inner tube. Be
careful not to damage the inner tube.
3. Check: 4
New 1
• Damper rod assembly
Damage/wear → Replace. 3
Obstruction → Blow out all of the oil passag-
es with compressed air.
• Oil flow stopper 2
Damage → Replace.
ECA14200
CAUTION:
• The front fork leg has a built-in damper ad- 2. Lubricate:
justing rod and a very sophisticated inter- • Inner tube’s outer surface
nal construction, which are particularly
sensitive to foreign material. Recommended oil
• When disassembling and assembling the Ohlins R & T43 (ACC-RT43F-00-
00)
front fork leg, do not allow any foreign ma-
terial to enter the front fork. 3. Tighten:
4. Check: • Damper rod assembly bolt
• Cap bolt O-ring
Damage/wear → Replace. Damper rod assembly bolt
T.
R.
35 Nm (3.5 m·kg, 25 ft·lb)
EAS23030 LOCTITE®
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the NOTE:
front fork legs.
EWA13660
While holding the damper rod assembly with the
WARNING damper rod holder “1”, tighten the damper rod
• Make sure the oil levels in both front fork assembly bolt.
legs are equal.
• Uneven oil levels can result in poor han- Damper rod holder
dling and a loss of stability. 90890-01447
YM-01447
NOTE:
• When assembling the front fork leg, be sure to
replace the following parts:
– Inner tube bushing
– Outer tube bushing 1
– Outer tube bushing 2
– Oil seal
– Dust seal
4-78
FRONT FORK
6. Install:
• Oil seal “1” New
(with the fork seal driver “2”)
Fork seal driver
90890-01502
YM-A0948
ECA14220
CAUTION:
4. Install: Make sure the numbered side of the oil seal
• Outer tube bushing 2 (D = 51 mm (2.01 in), l faces up.
= 15 mm (0.59 in)) “1” New NOTE:
(with the slide metal installer “2” and fork seal
• Before installing the oil seal, lubricate its lips
driver “3”)
with lithium-soap-based grease.
Slide metal installer • Lubricate the outer surface of the inner tube
90890-01508 with fork oil.
YM-01508 • Before installing the oil seal, cover the top of
Fork seal driver the front fork leg with a plastic bag to protect
90890-01502 the oil seal during installation.
YM-A0948
New 1
5. Install:
• Outer tube bushing 1 (D = 52 mm (2.05 in), l
= 12 mm (0.47 in)) “1” New
• Washer “2”
(with the fork seal driver “3”)
Fork seal driver
90890-01502
YM-A0948
7. Install:
• Oil seal clip “1” New
NOTE:
3 Adjust the oil seal clip so that it fits into the outer
tube’s groove.
New 1
4-79
FRONT FORK
8. Install: 11.Slowly stroke the inner tube “1” up and down.
• Dust seal “1” New
(with the fork seal driver “2”)
Fork seal driver
90890-01502
YM-A0948
12.Before measuring the fork oil level, wait ten
minutes until the oil has settled and the air
bubbles have dispersed.
NOTE:
Be sure to bleed the front fork leg of any residual
air.
9. Fill: 13.Measure:
• Front fork leg • Front fork leg oil level “a”
(with the specified amount of the recom- (from the top of the inner tube, with the outer
mended fork oil) tube fully compressed and without the fork
spring)
Recommended oil Out of specification → Correct.
Ohlins R & T43 (ACC-RT43F-00-
00) Level
Quantity 92.0 mm (3.62 in)
696.0 cm³ (23.53 US oz) (24.55
Imp.oz) NOTE:
ECA14230 • While filling the front fork leg, keep it upright.
CAUTION: • After filling, slowly pump the front fork leg up
• Be sure to use the recommended fork oil. and down to distribute the fork oil.
Other oils may have an adverse effect on
front fork performance.
• When disassembling and assembling the
a
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
10.After filling the front fork leg, slowly stroke the
damper rod assembly “1” up and down (at
least ten times) to distribute the fork oil.
NOTE:
Be sure to stroke the damper rod assembly 14.Install:
slowly because the fork oil may spurt out. • Fork spring
4-80