Honda 450X 2005 Owner's Manual & Competition Handbook page 118

Front Suspension Adjustments
8. Extend the fork damper piston rod to
maximum length. Adjust the oil level of the
fork damper as shown.
Oil Level: 1.65 – 1.85 in (42 – 47 mm)
(1)
1.65 – 1.85 in
(4)
(42 – 47 mm)
(1) fork damper (4) fork oil
9. Apply fork oil to the bushing (6) and new O-
ring (7) on the fork cap assembly (2).
Extend the fork damper piston rod to
maximum length, holding it, install the fork
cap assembly to the fork damper (1).
Be careful not to damage the fork cap bushing.
If it is difficult to install the fork cap assembly,
the fork damper oil level might be higher than
standard oil level. Inspect the fork damper oil
level again.
(2)
(6)
(1)
(1) fork damper (6) bushing
(2) fork cap assembly (7) O-ring
114
Adjustments for Competition
10.Tighten the fork cap assembly (2) while
holding the cut out of the fork damper (1)
using the lock nut wrench (3) to the specified
torque:
22 Ibf·ft (30 N·m, 3.1 kgf·m)
(1) fork damper
(2) fork cap assembly
11.Hold the fork damper (1) in an upright
position and pump the fork piston rod (5) to
3.9 in (100 mm) slowly several times.
(1)
(5)
(1) fork damper
(7)
(1)
(2)
(3)
(3) lock nut wrench
(5) piston rod
12.Screw in the lock nut (8) to the fork damper
piston rod (5) fully.
(5)
(5) piston rod (8) lock nut
Turn the rebound adjuster and compression
adjuster counterclockwise to the softest position.
Check the fork damper piston rod sliding surface
for damage.
Apply fork oil to the fork damper piston rod
sliding surface
Cover the fork piston rod end with soft jaws to
prevent fork damage.
NOTICE
Be careful not to bend or damage the fork
damper piston rod when the piston rod is stroked.
(8)