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Assembly
Replace the follow ing parts with new ones after remova
l.
Dust Seal
(A)
Re taining Ring
[
8
]
Oil Seal
[C)
Inner Guide Bush
[
0
]
OUler Guide Bush
[
E]
Cylinder Valve Assembly Gasket
[ F]
.Put the piston
rod
into the cylinder unit.
.Put the cylin der unit
[
A] into the
innenube
[
8] and install
t
he cylinder
base
[CJ
onto the bottom end of the cylinder unit protruding from the
inner tu
be.
O
lnsla!!
the cylinder base with the
ta
pered end
[0
] up.
el nsta
l1 the
inner
tube, cylinder unit, and
cylinder
base as a set into the
outer tube .
Install the new guide bush [A] with a used guide bush [elan
it
by
tapping the used guide bush wi th
t
he fork oil seal driver (
0
] until
it
stops.
o
rhe split [ B] of the bush
should
face
toward
the side of the vehicle.
Special Tool
-
Front Fork 011 Seat
Driver:
57001-1219
.
Apply molybdenum disulfide grease on the oil seal lips and install the
washer and the oil seal [A] inlO Ihe oUler tube.
Special Tool
-
Front Fork 011 Seal
Driver:
5700'-' 219
[
8
]
. lnSl
all:
Retaining
Ring
Dust Seal
.
Apply a non
-
permanent locking agent to the threa ds of the cylinder
valve assembly
and
screw the cylinder valve assembly into the bottom
of the
outer l
ube.
Hold
t
he inner cylinder with
t
he fork cylinder holder fA] and
tighten
the cylinder valve assembly (6].
Special Tool
-
Fork Cylinder
Holder:
57001-1245
Non-permanent Locking Agent
-
Threads of Cylinder Valve
Assembly
Torque
-
Cylinder Valve
Assembly:
71 N-m (7.2
kg-m,
52 ft-lb)
Pour
in
the specified type of oil and install the parts removed (see Fork
Oil Change)
.
SUSPENSION " -,,
~
8
-@
o
A
<==>
Front and Rear
A

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   Also See for Kawasaki KDX200

This manual is also suitable for:

Kdx220 1995-2006

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