1. | Support the motorcycle so the front end is off the floor and the forks are fully extended. | |||
2. | See the service manual. Remove the front fender, front brake caliper(s), and front wheel. | |||
3. | See the service manual. Remove the front forks. | |||
4. | See the service manual. Drain fork oil from the front forks. NOTE On some models, other parts need to be removed to access the front forks. See the service manual. | |||
![]() Wear safety glasses or goggles when servicing fork assembly. Do not remove slider tube caps without relieving spring preload or caps and springs can fly out, which could result in death or serious injury. (00297a) | ||||
5. | See the service manual. Disassemble the front fork tubes. Replace the original fork sliders with the chrome sliders (see Figure 2 , items 1 and 2) from the kit. | |||
6. | See the service manual. Assemble the front fork tubes. Replace worn seals, bushings or other items as needed. This kit includes new oil seals and tube cap O-rings. | |||
7. | See the service manual. Fill the forks with TYPE E FORK OIL (Part No. 99884-80). | |||
8. | See the service manual. Install the front forks. | |||
9. | See the service manual. Install the front fender, wheel, caliper and any parts that were removed to access the front forks. NOTE Remove and clean the original equipment front fork reflectors on both sliders for installation on the new sliders. Make sure ambient temperature is at least 60° F (16° C) for proper adhesion of the reflectors to the sliders. | |||
![]() Federal Motor Vehicle Safety Standard (FMVSS) 108 requires motorcycles to be equipped with rear and side reflectors. Be sure rear and side reflectors are properly mounted. Poor visibility of rider to other motorists can result in death or serious injury. (00336b) | ||||
10. | Using a piece of dental floss (or similar material) in a back and forth motion, loosen the reflector ( Figure 2 , A). Rotate the reflector from side to side until it can be removed from the fork slider. Retain the reflector for installation to the new slider. Repeat the procedure on the opposite side fork slider. | |||
11. | Remove any excess adhesive from both reflectors. Surface must be clean for reinstallation. NOTE Make sure that the bottom edge of the reflector is 50 mm (2 in) above the center of the axle shaft. |
Figure 1. Reflector Placement | ||
12. | Peel the liner from one side of the foam double-sided tape. Position the tape to the back of the reflector. Press firmly into place. Peel the remaining liner from the tape. Place the reflector in position on the fork slider as shown in Figure 1. Press firmly into place. Repeat the procedure on the opposite side fork slider. NOTE Allow AT LEAST 24 hours after applying the reflectors before exposing the area to vigorous washing, strong water spray or extreme weather. | |||
![]() Whenever a wheel is installed and before moving the motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00284a) | ||||
13. | Pump the brakes before test riding the motorcycle. | |||
14. | Test ride the vehicle to check fork travel and rebound. |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | Fork slider, left side, (chrome) | 45500239 |
2 | Fork slider, right side (chrome) | 45500240 |
3 | Oil seal (2) | 45378-87 |
4 | Tape, double sided foam (2) | 53791-06 |
5 | O-ring (2) | 45984-87 |
Items mentioned in text, but not included in kit: | ||
A | Reflector, left | 59482-00 |
B | Reflector, right | 59481-00 |