1. | Check the bores of the new sliders to verify that they are free of dirt and debris. | |||
2. | Support the motorcycle so the front end is off the floor and the forks are fully extended. | |||
3. | Remove front fender, front brake caliper(s), front wheel and front forks following the instructions in the service manual. NOTE Some models require that other parts be removed to access the front forks. See the service manual. | |||
WARNING 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) | ||||
4. | Disassemble the front fork tubes according to instructions in the service manual. | |||
5. | Replace the original fork sliders with the sliders (see Figure 2 , items 6 and 7) from the kit. | |||
6. | Assemble the front fork tubes, replacing worn seals, bushings or other items as needed. Two new slider oil seals (1) are included in the kit. | |||
7. | Fill with TYPE E FORK OIL (Part No. 99884-80) following the instructions in the service manual. | |||
8. | Install the front fork and any parts that were removed to access the front forks. Install the front fender, wheel and caliper according to the instructions in the service manual. NOTE Remove and clean the original equipment front fork reflectors on both sliders for installation on the new sliders. Ambient temperature should be at least 60° F (16° C) for proper adhesion of the reflectors to the sliders. |
Figure 1. Reflector Placement | ||
WARNING 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) | ||||
9. | See Figure 1. Use a piece of dental floss (or similar material) in a back and forth motion to loosen the reflector. Rotate reflector from side to side until it can be removed. Retain reflector for future use. Repeat procedure on the opposite side fork slider. | |||
10. | Remove any excess adhesive from both reflectors. Surface must be clean for installation. NOTE Position the bottom edge of the reflector 2.0 in (50 mm) above the center of the axle shaft. | |||
11. | Peel the liner from one side of the foam double-sided tape (5). 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. | |||
WARNING 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) | ||||
12. | Pump brakes before test riding vehicle. | |||
13. | Test ride the vehicle to verify proper fork travel and rebound. |
Kit | Item | Description (Quantity) | Part No. |
---|---|---|---|
Kit 45500267 (Chrome) | 1 | Oil seal (2) | 46514-01A |
2 | O-Ring (2) | 46508-01 | |
3 | Bolt (2) | 46614-06 | |
4 | Packing (2) | 46615-06 | |
5 | Tape, double sided foam (2) | 53791-06 | |
6 | Fork slider, left side (chrome) | 45500268 | |
7 | Fork slider, right side (chrome) | 45500270 | |
8 | Axle cap (chrome) | 45500272 | |
Kit 45500273 (Black) | 1 | Oil seal (2) | 46514-01A |
2 | O-Ring (2) | 46508-01 | |
3 | Bolt (2) | 46614-06 | |
4 | Packing (2) | 46615-06 | |
5 | Tape, double sided foam (2) | 53791-06 | |
6 | Fork slider, left side (black) | 45500269 | |
7 | Fork slider, right side (black) | 45500271 | |
8 | Axle cap (black) | 45500103 | |
Items mentioned in text but not included in kit: | |||
A | Reflector, left | ||
B | Reflector, right |