Insert the inner tube to the outer tube.
After installing the washer, install the oil seal [A] by using
the fork oil seal driver [B].
Special Tools - Fork Oil Seal Driver, 43: 57001-1530
or Fork Oil Seal Driver Weight,
Fork Oil Seal Driver Attachment, 36 ∼ 46:
Install the circlip and dust seal.
Apply a non-permanent locking agent (TB1344N or equiv-
alent) to the threads of the cylinder unit [A].
Install the cylinder unit into the inner tube.
Hold the axle portion of the front fork in a vise [A].
Tighten the cylinder unit by using the fork cylinder wrench
Special Tool - Fork Cylinder Wrench: 57001-1831
Torque - Cylinder Unit: 60 N·m (6.1 kgf·m, 44 ft·lb)
Pour in the specified type of oil (see Front Fork Oil
Inner Tube Inspection
Visually inspect the inner tube [A].
If there is any damage, replace the inner tube. Since
damage to the inner tube damages the oil seal and dust
seal, replace the oil seal and dust seal whenever the inner
tube is replaced.
If the inner tube is badly bent or creased, replace
Excessive bending, followed by subsequent
straightening, can weaken the inner tube.
Temporarily assemble the inner tube [A] and outer tube
[B], and pump [C] them back and forth manually to check
for smooth operation.
If you feel binding or catching, the inner and outer tubes
must be replaced.
A straightened inner or outer fork tube may fall in
use, possibly causing an accident resulting in seri-
ous injury or death. Replace a badly bent or dam-
aged inner or outer tube and inspect the other tube
carefully before reusing it.