Inside Circlip Pliers: 57001-143
Jack: 57001-1238
Fork
Cylinder Holder Handle: 57001-183
Fork Oil Seal Driver, 41: 57001-1288
Fork
Cylinder Holder Adapter: 57001-1057
Fork Oil Level Gauge: 57001-1290
Oil Seal & Bearing Remover: 57001-1058
Jack Attachment: 57001-1608
Bearing Driver Set: 57001-1129
Stem Bearing Driver, 28: 57001-1610
Special Tools
Spacer, 28:
57001-1663
Front Fork Removal
•
Remove:
Upper Inner Fairing (see Upper Inner Fairing Removal
in the Frame chapter)
Front Wheel (see Front Wheel Removal in the Wheels/Tires chapter)
Front Fender (see Front Fender Removal in the Frame chapter)
Front Wheel Rotation Sensor (see Front Wheel Rotation Sensor Removal in the Brakes chapter) (EX650B Mod- els)
Loosen the upper fork clamp bolt [A] and fork top plug [B] beforehand if the fork leg is to be disassembled.
NOTE
○Loosen the top plug after loosening the upper fork
clamp bolt.
• Loosen the upper fork clamp bolt and lower fork clamp bolts [C].
•
With a twisting motion, work the fork leg down and out.
Front Fork Installation
• Install the fork so that the top end [A] of the inner tube as shown.
10 mm (0.40 in.) [B]
• Tighten:
Torque - Front Fork Clamp Bolts (Lower): 20 N·m (2.0
kgf·m, 15 ft·lb)
Front Fork Top Plug: 25 N·m (2.5 kgf·m, 18 ft·lb)
NOTE
○Tighten the top plug before tightening the upper fork
clamp bolt.
○Tighten the two clamp bolts alternately two times to en-
sure even tightening torque.
• Tighten:
Torque - Front Fork Clamp Bolt (Upper): 20 N·m (2.0 kgf·m,
15 ft·lb)
•
Install the removed parts (see appropriate chapters).
Front Fork Oil Change
• Remove the front fork (see Front Fork Removal).
• Remove:
Top Plug [A] with O-ring
Collar [B]
Fork Spring Seat [C] Fork Spring [D]
• Compress [A] the fork [B] upside down to draw out the oil into the suitable container [C].
•
Pour in the specified amount of oil.
Fork Oil
Viscosity: kayaba khl34-g10 or equivalent
Amount (Per Side): When changing oil:
EX650A Models approx. 415 mL (14.0 US oz.) EX650B Models approx. 420 mL (14.2 US oz.)
After disassembly and completely dry:
EX650A Models 489 ±4 mL (16.5 ±0.14 US oz.)
EX650B Models 498 ±3 mL (16.8 ±0.10 US oz.)
NOTE
○Move the outer tube up and down a few times to remove
the air that is trapped in the fork oil in order to stabilize
the oil level.
•
Hold the outer tube vertically in a vise and compress
the fork completely.
• Wait until the oil level stabilizes.
• Use the fork oil level gauge [A] to measure the distance
between the top of the inner tube to the oil level.
Special Tool - Fork Oil Level Gauge: 57001-1290
○Set the oil level gauge stopper [B] so that the distance [C] from the bottom of the stopper to the lower end of the pipe is the standard oil level distance.
○A correct measurement can not be obtained unless the
level gauge pipe is placed in the center of the inner tube.
Oil Level (fully compressed, without spring) Standard:
EX650A Models 98 ±2 mm (3.9 ±0.08 in.)
EX650B Models 89 ±2 mm (3.5 ±0.08 in.)
○Place the stopper of the level gauge at the top [D] of the inner tube [E] and pull the handle slowly to draw out the excess oil from fork into the gauge, thus attaining the stan- dard level.
○If not oil is drawn out, there is not enough oil in the fork.
Pour in some more oil and measure again.
•
Repeat the same procedure for adjusting the other fork.
• Install the fork spring [A], fork spring seat [B] and collar
[C].
• Inspect the top plug O-ring and replace it with a new one.
• Install the front fork (see Front Fork Installation).
Front
Fork Disassembly
• Remove the front fork (see Front Fork Removal).
• Remove the top plug [A] with O-ring, take out the collar
[B], fork spring seat [C], and fork spring [D].
• Drain the fork oil (see Front Fork Oil Change).
•
Remove the Allen bolt [A] from the bottom of the fork.
Special Tools - Fork Cylinder Holder Handle [B]: 57001-183
Fork Cylinder Holder Adapter [C]: 57001
-1057
NOTE
○Hold the outer tube in a vise [D], stop the cylinder unit
[E] from turning by using the special tools, and unscrew
the Allen bolt.
•
Remove the cylinder unit [A], washer, and the spring [B] from
the inner tube.
•
Remove the following from the top of the outer tube.
Dust Seal [A]
Retaining Ring [B]
•
Separate the inner tube [A] from the outer tube [B].
NOTE
○From the compressed state, firmly pull down the outer
tube a few times towards the direction of elongation.
•
Remove the following from the inner tube. Inner Guide
Bushing [A]
Outer Guide Bushing [B] Washer [C]
Oil Seal [D]
•
Remove the
cylinder base
[A] from
the bottom
of the
outer tube.
Front
Fork Assembly
• Check the top plug O-ring and replace it with a new one.
• Replace the following parts with new ones.
Retaining Ring [A]
Dust Seal [B] Oil Seal [C]
Inner Guide Bushing [D] Outer Guide Bushing [E]
Fork Bottom Allen Bolt Gasket [F]
•
Install the guide bushing on the end of the inner tube.
• Insert the cylinder unit and the spring into the inner tube,
and install the cylinder base [A] onto the cylinder end [B]
that protrudes from the bottom.
○Install the cylinder base starting with its stepped end.
• Insert the inner tube, cylinder unit, washer, spring, and cylinder base as a set into the outer tube.
•
Install the guide bushing into the outer tube.
• After installing the washer, install the oil seal [A] by using
the fork oil seal driver [B].
Special Tool - Fork Oil Seal Driver, 41: 57001-1288
• Install the retaining ring into the outer tube.
• Install the dust seal by hand.
•
Apply non-permanent locking agent to the threads of the
bottom Allen bolt [A].
• Hold the front fork horizontally in a vise [B].
• Hold the cylinder unit [C] with the special tools and tighten
the bottom Allen bolt to secure the cylinder in place.
Torque - Front Fork Bottom Allen Bolt: 30 N·m (3.1 kgf·m, 22 ft·lb)
Special Tools - Fork Cylinder Holder Handle [D]: 57001-183 Fork Cylinder Holder Adapter [E]: 57001
-1057
• Pour in the specified type of oil (see Front Fork Oil Change).