Honda CRF450R 2009 Owner's Manual & Competition Handbook page 125

14. Install a new O-ring (13) on the fork damper
assembly (4). Apply the recommended fork
oil to the O-ring.
15. Pull up the fork assembly (1) slowly and
install the fork damper assembly (4) into the
outer tube.
(13)
(1)
(1) fork assembly (13) O-ring
(4) fork damper assembly
16. Insert both fork legs into the fork clamps.
Tighten the fork bridge lower pinch bolts (14)
to the specified torque:
15 Ibf·ft (20 N·m, 2.0 kgf·m)
(14) fork bridge lower pinch bolts
17. Tighten the fork damper (15) to the specified
torque using the lock nut wrench (16).
Actual:
22 lbf·ft (30 N·m, 3.1 kgf·m)
Torque wrench scale reading:
20 Ibf·ft (27 N·m, 2.8 kgf·m), using a 20 in
(50 cm) long deflecting beam type torque
wrench.
• Lock nut wrench
(4) When using the lock nut wrench, use a 20 in (50
cm) long deflecting beam type torque wrench.
The lock nut wrench increases the torque
wrench's leverage, so the torque wrench reading
will be less than the torque actually applied to the
fork damper.
(15)
(15) fork damper
18. For ease of releasing air pressure after the
forks are installed, loosen the fork bridge
lower pinch bolts and position the outer tubes
so that the fork air pressure release screws are
in front of the compression damping adjusters.
(14)
Align the top of the outer tube (17) with the
top surface of the top bridge (18).
Front Suspension Adjustments
070MA-MEN0100
(17) outer tube
19. Tighten the fork bride lower pinch bolts (14)
20. Tighten the fork bridge upper pinch bolts (19)
(16)
NOTICE
Over-tightening the pinch bolts can deform the
outer tubes. Deformed outer tubes must be
replaced.
(16) lock nut wrench
(14) fork bridge lower
(18)
(17)
(18) top bridge
to the specified torque:
15 Ibf·ft (20 N·m, 2.0 kgf·m)
to the specified torque:
16 Ibf·ft (22 N·m, 2.2 kgf·m)
(19)
(14)
(19) fork bridge upper
pinch bolts pinch bolts
Adjustments for Competition
(cont'd)
119