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

○Setthe 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).

Inner Tube Inspection

• Visually inspect the inner tube [A], and repair any dam- age.

• Nicks or rust damage can sometimes be repaired by using

a wet-stone to remove sharp edges or raised areas which

cause seal damage.

CAUTION

If the inner tube is badly bent or creased, replace it. Excessive bending, followed by subsequent straightening, can weaken the inner tube.

If the damage is not repairable, replace the inner tube. Since damage to the inner tube damages the oil seal, replace the oil seal whenever the inner tube is repaired or replaced.

• Temporarily assemble the inner and outer tubes, and pump them back and forth manually to check for smooth

operation.

WARNING

A straightened inner or outer fork tube may fall in use, possibly causing an accident. Replace a badly bent or damaged inner or outer tube and inspect the other tube carefully before reusing it.

• If you feel binding or catching, the inner and outer tubes must be replaced.

Dust Seal Inspection

• Inspect the dust seal [A] for any signs of deterioration or damage.

Replace it if necessary.

 

 

Fork Spring Inspection

• Measure the free length [A] of the fork spring [B].

If the measured length is shorter than the service limit, the

spring must be replaced. If the free length of the replace- ment spring and that of the remaining spring vary greatly, the remaining spring should also be replaced in order to keep the fork legs balanced to ensure stability.

Fork Spring Free Length

Standard: 277.2 mm (10.91 in.)