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Table of Contents
110 DISASSEMBLY-CHASSIS
FRONT
FORK
Removal
(each
fork leg):
•Remove the
front wheel
(Pg.
89).
•Remove the front fender.
··
•To remove
the
left fork
leg, remove
the caliper
mount-
ing bolts,
loc
kwashers, and
flat washers (2 ea); and
put
the
caliper aside.
•Loosen the
upper and lower clamp
bolts.
A
.
Upper
Clamp
Bolt
B. Lower Clamp Bolt
•With a twisting
motion,
work
the
fork leg down
and
out
Installation
(each fork leg):
•Slide the fork leg up th rough
the
lower and
upper
clamp~
until
the
upper end of
the fork
tube
is
even
with the upper surface
of the
stem
head.
Tighten
the
upper clamp
bolt to 1.8
kg-m
(13.0 ft-lbs}
and
the lower
clamp
bol
t
to
2.5 kg-m ('18.0 ft-lbs).
A
.
Upper Clamp Bolt
B. Stem Head
I nstal
I
the
fender
between the
fork
legs.
•Install
the
caliper,
tigh tening
the
cali per mounting
bolts
to 3.0
kg·m
(22
ft-lbs) of torque. Each mounting
bolt
has a
flat washer
and
lockwasher.
•Secure the lower brake
hose
in
its
guide.
Be
sure the
rubber
grommet
is in
place.
•Install
the fron
t
wheel.
Disassembly:
•Remove the
cap
IS
from
the inner
tube.
•Press the
top
plug
ii
to remove
the
top plug retaining
ring
'ii
,
and
remove the
top
plug,
0
ring
'i
§·, and
spring
A. Top Plug
C. Press down.
B. Retaining Ring
•Pour
the
oil
into
a suitable
container,
pumping as
necessary
to
empty out al
l
the
oil.
•Using the
front
fork cylinder holder
handle
and
holder
adapter
(special
tools) to keep
the cylinder
from
turning,
unscrew
the
Allen
bolt
'li.
and
gasket
1)
from
the bottom
of the outer
tube
·' 1
./
or
'30,
,
and then separate
the inner tube from the
outer
tube
by
pulling
it out.
A. Front Fork Cylinder Holder Handle and Adapter
(57001-183,
57001-1011)
B.
Allen
Wrench
•Remove
the
dust
seal
YJ;
from
the ou ter
tube
f
'
.
•Slide
or push the cylinder
~
and its spring
·_{
out
the
top of
the
inner
tu
be.
• Remove
the
retain
er
'i4
from the outer tu
be
with
a
sharp
hook,
and pull out
the
oil
seal
:~
.
' :
.
It may be
necessary to
heat
the outer
tube
around the
oil
seal
before pu
lli
ng
it
out. Then
pull the spacer
~
~
-
from
the
outer tube.

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Table of Contents

   Also See for Kawasaki Z250 1981

This manual is also suitable for:

Kz350 1981

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