Front Fork (KX450D8F)
Raise the outer tube and temporarily tighten the fork top
Special Tool - Top Plug Wrench, 49 mm: 57001-1653
After installing the front fork, torque the top plug [A].
Special Tool - Top Plug Wrench, 49 mm: 57001-1653 [B]
The torque of fork top plug is specified to 30 N·m (3.1
kgf·m, 22 ft·lb), however, when you use the top plug
wrench (special tool) [A] reduce the torque to 90% of the
specified value [27 N·m (2.8 kgf·m, 20 ft·lb)] due to the
distance [B] between the center of the square hole, where
the torque wrench is fitted, and that of the octagonal hole
of the wrench.
This torque value [27 N·m (2.8 kgf·m, 20 ft·lb)] is appli-
cable when you use a torque wrench whose length gives
leverage of approximately 310 mm between the grip point
to the center of the coupling square.
Torque - Front Fork Top Plug: 30 N·m (3.1 kgf·m, 22 ft·lb)
Adjuster Assembly Inspection
Inspect the adjuster assembly [A] and push rod [B] for
If they are damaged, replace them with new ones.
Replace the gasket [C] and O-ring [D] on the adjuster as-
sembly with new ones.
Base Valve Assembly Inspection
Inspect the threads portion [A], bushing [B], O-ring [C] and
spring [D] of base valve assembly [E] for damage.
If they are damaged, replace base valve assembly with
Replace the O-rings [F] with new ones.