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Front Fork Installation; Front Fork Disassembly (each Fork ) - Kawasaki KLX110 Service Manual

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12-8 SUSPENSION
Front Fork
Remove the number plate.
Loosen the upper and lower fork clamp bolts [A].
With a twisting motion, work the fork leg down and out.

Front Fork Installation

If the fork leg was disassembled, check the fork oil level.
Install the fork, aligning the top end [A] of the inner tube with the
upper surface [B] of the steering stem head.
Route the cables and hose according to the Cable, Harness, Hose
Routing section in the General Information chapter.
Install the front wheel (see Wheels/Tires chapter).
Tighten the following:
Torque -
Upper Fork Clamp Bolts: 20 N
Lower Fork Clamp Bolts: 29 N
Check the front brake operation after installation.

Front Fork Disassembly (each fork )

Remove the front fork (see this chapter).
Remove the top plug and the fork spring.
Remove the dust seal.
Drain the fork oil with the fork upside down (see Fork Oil Change)
Hold the outer tube [A] in a vise.
Stop the cylinder [B] from turning by using the front fork cylinder
holder.
Special Tool -
Fork Cylinder Holder Handle: 57001–183 [C]
Fork Cylinder Holder Adapter: 57001–1011 [D]
Unscrew the Allen bolt [E], then take the bolt and gasket out of the
bottom of the outer tube.
Remove the cylinder unit [A] and spring [B] from the fork.
Separate the inner tube [A] from the outer tube [B] by pulling them
out.
m (2.0 kgf
m, 15 ft
lb)
1
1
1
m (3.0 kgf
m, 22 ft
lb)
1
1
1

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