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Front Fork Assembly (each Fork) - Kawasaki KLX110 Service Manual

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Front Fork
Take the cylinder base [A] out of the outer tube [B].
Remove the retaining ring [A] from the outer tube.
Remove the oil seal [B].
Special Tool -
Oil Seal & Bearing Remover: 57001–1058

Front Fork Assembly (each fork)

Assembly is the reverse of disassembly.
Replace the following parts removed with a new one.
Retaining Ring
Oil Seal
Bottom Allen Bolt Washer
Inspect the following and replace them with new ones if damaged.
Inner Tube (see Inner Tube Insspection)
Top Plug O-ring
Insert the cylinder unit and spring in the inner tube.
Insert the cylinder base [A] in the cylinder unit [B].
The cylinder base must be installed with the tapered side facing
upward.
Insert the inner tube and cylinder unit as a set into the outer tube.
Apply a non-permanent locking agent to the bottom Allen bolt and
tighten it to the specified torque, using the front fork cylinder holder.
Torque -
Bottom Allen Bolts: 20 N
Special Tool -
Fork Cylinder Holder Handle: 57001–183
Fork Cylinder Holder Adapter: 57001–1011
Install the oil seal [A] by tapping with the fork oil seal driver [B] until
it stops.
Special Tool -
Fork Oil Seal Driver: 57001–1219
Install the following.
Retainer
Dust Seal
m (2.0kgf
m, 15ft
lb)
1
1
1
SUSPENSION 12-9

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