Front Fork (KX450D6F ∼ D7F)
Insert the push rod [A] into the piston rod.
Replace the O-ring and gasket on the adjuster assembly
with new ones and apply specified fork oil to the O-ring.
Slowly turn the adjuster assembly [A] clockwise until re-
sistance is felt and check the clearance between the lock-
nut [B] and adjuster assembly [A] to provide more than 1
mm (0.04 in.) [C].
Turn the locknut [A] counterclockwise until it contacts with
the adjuster assembly [B].
With the locknut held immovable using a wrench, tighten
the adjuster assembly to the specified torque.
Torque - Locknut/Adjuster Assembly: 29 N·m (3.0 kgf·m, 21
With the outer tube compressed by hands, remove the
top plug wrench.
Apply a non-permanent locking agent to the threads of
Torque the adjuster assembly [A].
Torque - Adjuster Assembly: 58 N·m (5.9 kgf·m, 43 ft·lb)
Loosen and remove the fork top plug (subtank) from the
outer tube and slowly slide down the outer tube.
Special Tool - Top Plug Wrench, 49 mm: 57001-1653
Pour [A] the specified amount of fork oil into the outer
KHL15-10 (KAYABA01) or
345 mL (11.7 US oz) (KX450D6F)
(Europe Model) 350 mL (11.8 US
355 ml (12.00 US oz) (KX450D7F)