5-19
FRONT FORK
CHECKING THE BASE VALVE
1. Inspect:• Base valve "1"Wear/damage
→Replace.
Contamination
→Clean.
• O-ring "2" Wear/damage
→Replace.
• Piston metal "3" Wear/damage
→Replace.
• Spring "4"
Damage/fatigue
→Replace base
valve.
• Air bleed screw "5"
Wear/damage
→Replace.
CHECKING THE COLLAR
1. Inspect: • Piston metal "1"Wear/damage
→Replace.
CHECKING THE FORK SPRING
1. Measure: • Fork spring free length "a"Out of specification
→Replace.
CHECKING THE INNER TUBE
1. Inspect: • Inner tube surface "a"Score marks
→Repair or replace.
Use #1,000 grit wet sandpaper.
Damaged oil lock piece
→Re-
place.
• Inner tube bends
Out of specification
→Replace. Use the dial gauge "1".
The bending value is shown by one
half of the dial gauge reading.
Do not attempt to straighten a bent
inner tube as this may dangerous-
ly weaken the tube.
CHECKING THE OUTER TUBE
1. Inspect:
• Outer tube "1"
Score marks/wear/damage
→Re-
place.
CHECKING THE ADJUSTER
1. Inspect: • Adjuster "1"
• O-ring "2"Wear/damage
→Replace.
ASSEMBLING THE FRONT FORK
1. Wash the all parts in a clean sol- vent.
2. Stretch the damper assembly ful- ly.
3. Fill: • Front fork oil "1"To damper assembly.
• Be sure to use recommended fork oil. If other oils are used,
they may have an excessively ad-
verse effect on the front fork per-
formance.
• Never allow foreign materials to enter the front fork.
4. After filling, pump the damper as- sembly "1" slowly up and down
(about 200 mm (7.9 in) stroke)
several times to bleed the damper
assembly of air.
Be careful not to excessive full stroke.
A stroke of 200 mm (7.9 in) or more
will cause air to enter. In this case, re-
peat the steps 2 to 4.
5. Measure:
• Oil level (left and right) "a"Out of specification
→ Adjust.
Fork spring free length:
454 mm (17.9 in)
: 449 mm (17.7
in)
Inner tube bending limit:0.2 mm (0.008 in)
Recommended oil: Suspension oil "S1"
Oil capacity: 199 cm
3 (7.00 Imp oz,
6.73 US oz)
Standard oil level: 145-148 mm (5.71-5.83
in)
From top of fully
stretched damper as-
sembly.
