dummyhead

FRONT WHEEL/SUSPENSION/STEERING
INSTALLATION
Install the side collars [1] to the front wheel.
Right side: [1] Left side: [5]
Apply a thin coat of grease to the front axle sliding
surface. [1]

Install the front wheel between the forks.

Align the surfaces of Install the front axle [2] from right side.
the axle and right
Tighten the right front axle holder pinch bolts [4] to the
fork [3] as shown.
specified torque.
TORQUE: 22 N·m (2.2 kgf·m, 16 lbf·ft)
Install and tighten the axle nut [5] to the specified
torque.
TORQUE: 60 N·m (6.1 kgf·m, 44 lbf·ft) [2] [4] [6] [7]

Loosen the right front axle holder pinch bolts.

Tighten the left front axle holder pinch bolts [6] to the
specified torque.
TORQUE: 22 N·m (2.2 kgf·m, 16 lbf·ft)
Install the front brake calipers (page 19-18).
With the front brake applied, pump the forks up and
down several times to seat the axle and check brake
operation.
Tighten the right front axle holder pinch bolts to the
specified torque.
TORQUE: 22 N·m (2.2 kgf·m, 16 lbf·ft) [3] [2]
ED model: Install the axle cap [7].
Check the clearance gap between the front wheel
speed sensor bracket and pulser ring (page 20-21).

FORK
REMOVAL
Remove the following:
[2] [1]
– Front fender (page 2-9)
– Front wheel (page 17-10)
– Front speed sensor (CRF1000A/D) (page 20-20)
Loosen the top bridge pinch bolts [1]. [3]
Be careful not to If the fork will be disassembled, loosen the fork bolts [2]
damage the fork at this point, but do not remove yet.
bolt when loosening
Loosen the fork bottom bridge pinch bolts [3] by holding
it.
the forks then remove it.

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FRONT WHEEL/SUSPENSION/STEERING
When disassembling the fork, turn the pre-load adjuster
[1] and rebound adjuster [2] counterclockwise to the
softest position (be sure to record the number of turns
from the starting position). [2]
[1]

DISASSEMBLY
Be careful not to Remove the fork bolt [1].
damage the fork
bolt when removing
it.

[1]

Push the outer pipe [1] slowly down, and gently seat the
[1]
dust seal [2] onto the axle holder [3].

[2]

[3]

Attach the special tool to the spring collar holes [1].

[2]
TOOL:
Spring collar holder [2] 070MF-MBZC110
Compress the spring collar [3] with the spring collar [5]
holder.
Insert the special tool between the lock nut [4] and
spring collar.
[4]
TOOL:
Stopper plate [5] 070MF-MBZC130

[3] [1]

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FRONT WHEEL/SUSPENSION/STEERING
Be careful not to Loosen the fork bolt [1] while holding the lock nut [2].
[1]
damage the fork
bolt when loosening
it.

[2]

Remove the following:

[2]
– Fork bolt assembly [1]
[1]
– O-ring [2]
– Spring seat stopper [3] [3]

Remove the stopper plate [4] and spring collar holder

[5].
Remove the spring collar [6]. [4]

[5]

[6]

Pour out the fork fluid by pumping the outer pipe [1]
[1] [2]
several times.
Pour out the fork fluid from the fork damper by pumping
the damper rod [2] several times.
Remove the fork spring [3].

[3]

Hold the axle holder in a vise with soft jaws or a shop

[1]/[2]
towel.
Remove the fork center bolt [1] and sealing washer [2].

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FRONT WHEEL/SUSPENSION/STEERING
Remove the fork damper assembly [1] and centering
[2] [1]
plate [2].

Remove the dust seal [1].

Do not scratch the Remove the oil seal stopper ring [2].
fork pipe sliding [2]
surface.

[1]

Pull the slide pipe assembly [1] out until you feel
[2]
resistance from the slider bushing. Then move it in and
out, tapping the bushing lightly until the outer pipe [2]
separates from the slide pipe assembly.
The guide bushing will be forced out by the slider
bushing.

[1]

Remove the following:

[6] [4] [2] [1]
– Slider bushing [1]
– Guide bushing [2]
– Back-up ring [3]
– Oil seal [4]
– Stopper ring [5]
– Dust seal [6]

• Do not remove the slider bushing unless it is

necessary to replace with a new one.

[5] [3]

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FRONT WHEEL/SUSPENSION/STEERING
INSPECTION
Inspect the following parts for damage, abnormal wear,
deformation, looseness or bend.
– Fork bolt assembly
– Outer pipe/slide pipe assembly
– Fork dumper
– Spring seat stopper
– Spring collar
– Fork spring
– Guide bushing
– Slider bushing
– Back-up ring
Measure each part according to FRONT WHEEL/
SUSPENSION/STEERING SPECIFICATIONS
(page 1-10).
Replace any part if it is out of service limit.

ASSEMBLY
FORK DAMPER LOCK NUT FORK BOLT ASSEMBLY
FORK DAMPER 35 N·m (3.6 kgf·m, 26 lbf·ft)
20 N·m (2.0 kgf·m, 15 lbf·ft)
SLIDE PIPE
ASSEMBLY SPRING SEAT
STOPPER
SLIDER
BUSHING
FORK AXLE HOLDER
GUIDE
PINCH BOLTS
BUSHING
22 N·m (2.2 kgf·m, 16 lbf·ft)
BACK-UP
RING

OUTER
PIPE O-RING
OIL
SEAL

STOPPER
RING

DUST SEAL

SEALING SPRING COLLAR

FORK CENTER BOLT WASHER
34 N·m (3.5 kgf·m, 25 lbf·ft) CENTERING PLATE FORK SPRING

• Before assembly, wash all parts with a high flash

point or non-flammable solvent and blow them dry.
• When installing the fork dust seal and oil seal, wrap
the edge and groove of the slide pipe with tape [1].

[1]

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FRONT WHEEL/SUSPENSION/STEERING
Apply fork fluid to new dust seal and oil seal lips.
[2] [3] [6] [8]
Install the oil seal Install the dust seal [1], stopper ring [2] and oil seal [3].
with its marked side
Install the back-up ring [4], guide bushing [5].
facing toward the
axle holder. Install the slider bushing [6] if it is removed.

• Remove any burrs from the bushing mating surface,

being careful not to peel off the coating.
• Do not open the slider bushing slit more than
necessary.
Install the slide pipe assembly [7] into the outer pipe [8]. [1]

[4] [5] [7]

Put the guide bushing [1], back-up ring [2] and oil seal
[3] on the outer pipe. [5]
Put the special tool on the oil seal.
TOOL: [3]
Fork seal driver, 45.2 mm [4] 07KMD-KZ30100 [4]
See illustration for Drive the oil seal with the guide bushing and back-up
correct seating. ring into the outer pipe until the stopper ring groove [5]
is visible using the special tools. [2]

[1]

Do not scratch the Install the stopper ring [1] into the groove securely.
fork pipe sliding
Install the dust seal [2].
surface. [2]

[1]

Install the fork damper assembly [1] and centering plate

[2] [1]
[2].

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FRONT WHEEL/SUSPENSION/STEERING
Install the socket bolt [1] with a new sealing washer [2].
[1]/[2]
Hold the axle holder in a vise with soft jaws or a shop
towel.
Tighten the center bolt to the specified torque.
TORQUE: 34 N·m (3.5 kgf·m, 25 lbf·ft)

Pour the specified amount of recommended fork fluid.

RECOMMENDED FORK FLUID:

Honda Ultra Cushion Oil 10W (SS-47)
FORK FLUID CAPACITY:
721 ± 2.5 cm3 (24.4 ± 0.1 US oz, 25.4 ± 0.1 Imp oz)

Bleed the air from the fork as follows:

[1]
1. Extend the fork, cover the top of the outer pipe [1] [3]
with your hand and compress the fork slowly.
2. Remove your hand and extend the fork slowly.
Repeat above procedure 2 or 3 times. [2]
3. Install the special tool to the fork damper rod [2].
TOOL: [1]
Damper rod holder [3] 070MF-MBZC120
Pump the fork damper rod slowly 8 – 10 times.

Slowly push the outer pipe [1], and gently seat the dust
seal [2] onto the axle holder [3] and leave it for 5
minutes. [1]
Be sure the oil level After the oil level stabilizes, measure the oil level from
is the same in the the top of the outer pipe.
both forks.
FORK FLUID LEVEL:
95.0 mm (3.74 in)

[3] [2]

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FRONT WHEEL/SUSPENSION/STEERING
Install the fork spring [1] into the slide pipe assembly
with the tightly wound side facing down. [3]
[1]
Install the spring collar [2] and spring seat stopper [3].

[2]

[1]

Down

Clench the lock nut [1] until it is fully seated.

[1]
Attach the special tool to the spring collar holes [2]. [4]
TOOL:
Spring collar holder [3] 070MF-MBZC110 [7]
While pulling the damper rod holder [4] up, compress
the spring collar [5] with the special tool.
[6]
Insert the special tool between the lock nut and spring
seat stopper [6]. [3]

TOOL:
Stopper plate [7] 070MF-MBZC130
Remove the damper rod holder. [5] [2]

When installing the fork bolt assembly [1], turn the

[2]
rebound adjuster [2] counterclockwise to the softest
position.
[3]
Apply fork fluid to a new O-ring [3] and install it to the
fork bolt assembly.
Install the fork bolt assembly to the fork damper until it
is fully seated. [1]

Be careful not to Tighten the fork bolt to the specified torque while
damage the fork holding the lock nut [1].
bolt when tightening
it. TORQUE: 20 N·m (2.0 kgf·m, 15 lbf·ft)
Remove the stopper plate [2] and spring collar holder
[3].
[1]

[2]

[3]

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FRONT WHEEL/SUSPENSION/STEERING
Tighten the fork bolt Install the fork bolt [1].
[1]
after installing the
fork slider into the
steering stem.

INSTALLATION
Install the forks through the bottom bridge and top
[2] [4] [5]
bridge so that the end of the outer pipe [1] is aligned
with the top bridge [2] upper surface.
Tighten the bottom bridge pinch bolts [3] to the
specified torque.
[3]
TORQUE: 25 N·m (2.5 kgf·m, 18 lbf·ft)

Be careful not to If the fork bolt [4] is loosened, tighten it to the specified
damage the fork torque. [1]
bolt when tightening
it.
TORQUE: 35 N·m (3.6 kgf·m, 26 lbf·ft)
Tighten the top bridge pinch bolts [5] to the specified
torque.
TORQUE: 22 N·m (2.2 kgf·m, 16 lbf·ft)
Return the pre-load and rebound damping adjusters to
the original positions as noted during disassembly.
– Front speed sensor (CRF1000A/D) (page 20-20)
– Front wheel (page 17-14)
– Front fender (page 2-9)

STEERING STEM
REMOVAL
Remove the air cleaner case (page 7-11).
Remove the handlebar lower holder (page 17-7).
Disconnect the immobilizer receiver 4P (Black) [1] and
ignition switch 2P (Brown) [2] connectors.
[1]

[2]

17-22