2-54 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Replace the O-rings [A] on the base valve assembly with
Apply specified fork oil to the O-rings and bushings [B].
Do not damage the bushings when assembling the
With the piston rod [A] appear about 20 mm (0.79 in.) from
fully compressed, gently install the base valve assembly
[B] slowly to the cylinder unit [C].
Plug the oil holes [D] on the left front fork cylinder unit
While pulling the piston rod, install the base valve as-
sembly slowly and pushing down it fully.
Hold the top plug wrench (57001-1645) [A] with a vise.
Holding the cylinder unit [B] with the top plug wrench
(57001-1645), torque the base valve assembly [C] to the
specified torque. With the top plug wrench (57001-1810)
Special Tools - Top Plug Wrench, 50 mm: 57001-1645
Top Plug Wrench, 36 mm: 57001-1810
Torque - Base Valve Assembly: 30 N·m (3.1 kgf·m, 22 ft·lb)
Check if the locknut is completely screwed on to the
Protect the piston rod end [A] with a heavy cloth [B] to
prevent piston rod thread damage.
Hold the cylinder unit at the upright position and slowly
pump the piston rod several times about 100 mm (3.94
Drain the extra oil off the cylinder unit by pumping the
piston rod to full stroke.
Be careful not to bend or damage the piston rod
when the piston rod is stroked. Service carefully
because oil flows out from the oil hole of the cylin-
Set the compression damping force setting to the soft-
Check the piston rod sliding surface for damage.
Apply fork oil to the piston rod sliding surface.