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Front Fork Disassembly (each Fork Leg) - Kawasaki KLX110 Service Manual

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Front Fork

Front Fork Disassembly (each fork leg)

Remove the cap.
Loosen the front fork upper clamp bolt [A].
Remove the snap ring [B] while pressing the top plug [C],
and then remove the top plug with O-ring.
Remove the front fork (see Front Fork Removal).
Thoroughly clean the fork before disassembly.
Be careful not scratch the inner tube and not to
damage the dust seal.
Avoid scratching or damaging the inner tube or the
dust seal. Use a mild detergent and sponge out dirt
with plenty of water.
Fork Spring
Dust Seal
Drain the fork oil [A] with the fork upside down.
Pump the fork tube several times to discharge the oil.
Hold the outer tube horizontally in a vice.
Stop the cylinder [A] from turning by using the fork cylinder
holder handle [B] and adapter [C].
Special Tools - Fork Cylinder Holder Handle: 57001-183
Fork Cylinder Holder Adapter: 57001-1011
Unscrew the Allen bolt [D], then take out the bolt and gas-
ket from the bottom of the outer tube.
Remove the cylinder unit [A] and spring [B] from the fork.


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