1. | Install front forks from kit to motorcycle according to service manual instructions but do not tighten the fork bracket pinch screws at this time. | |
2. | See Figure 1. Measure the distance from the top of upper fork bracket to top of fork assembly. Both sides must be exactly the same and measure 0.388-0.468 inch (9.85-11.89 mm) above the top fork bracket. Align the adjustment screws inline with the handlebars (see Figure 5). NOTE If new pinch screws are not readily available, use a wire grinder wheel to remove all remaining lock patch from original pinch screws, wash screws in clean solvent and dry thoroughly. Apply two drops of LOCTITE® 262 to the first 1/4 in. (6.35 mm) of the end threads. | Figure 1. Fork Installation Height Measurement. |
3. | Install pinch screws to upper and lower fork brackets. | |
4. | Verify fork tube installation measurement is 0.388-0.468 inch (9.85-11.89 mm). | |
5. | Tighten pinch screws to 40.7–47.5 N·m (30–35 ft-lbs). NOTE See Figure 2. The top edge of reflector should be 1-1/2 inches (38.10 mm) below the lower edge of the bottom fork clamp. | Figure 2. Attaching Reflectors to Fork Sliders |
6. | Remove the adhesive backing. Place reflector in position and press reflector firmly into place to activate the adhesive. Repeat for reflector on opposite fork. |
1. | See Figure 3. Install the rear shock absorbers according to service manual instructions. The shocks are installed with the external gas reservoir to the rear of the shock absorbers and the thick side of the grommet installed to the frame rail mounts. | Figure 3. Install Thick Side Of Grommet To Frame Rail |
1. | Front fork preload adjustment: | Figure 4. Fork Preload Adjuster | ||||
2. | Front rebound damping adjustment: | |||||
3. | Front fork compression damping adjustment: |
Figure 5. Fork Rebound and Compression Damping Adjusters |
RIDER WEIGHT | PRELOAD* |
---|---|
Less than 75 kg (165 lb) | 0-4 turns in |
75–89 kg (165–195 lb) | 4-6 turns in |
89–102 kg (195–225 lb) | 6-8 turns in |
102–116 kg (225–255 lb) | 8-10 turns in |
Greater than 116 kg (255 lb) | More than 10 turns |
*Values shown are clockwise turns in from minimum. Rotate adjuster clockwise to increase preload or counterclockwise to decrease preload. |
DAMPING* | NOMINAL (FROM MAXIMUM) |
---|---|
Rebound (REB) | 3 turns |
Compression (COM) | 5 turns |
*Values shown are counterclockwise turns out from maximum. Rotate adjuster clockwise to increase damping or counterclockwise to decrease damping. |
1 | Preload adjusting cam |
2 | Compression damping adjuster |
3 | Pressurized gas valve (do not remove cover) |
4 | Spanner wrench |
1 | Minimum preload adjustment |
2 | Maximum preload adjustment |
RIDER WEIGHT | PRELOAD |
---|---|
Less than 75 kg (165 lb) | Position 1 |
75–89 kg (165–195 lb) | Position 2 |
89–102 kg (195–225 lb) | Position 3 |
102–116 kg (225–255 lb) | Position 4 |
Greater than 116 kg (255 lb) | Position 5 |
DAMPING | NOMINAL (From Maximum) |
---|---|
Compression (COM) | 7 clicks |
Rebound (REB) | 5 clicks |
1. | Set the front forks and shock absorbers to the recommended settings. Properly inflate the tires. | |
2. | Determine the ride quality of the motorcycle. Ride the motorcycle on a familiar road with a variety of bumps and turns. Ride over different surfaces at varying speeds. If the suspension is set properly, the vehicle suspension will feel controlled and comfortable. | |
3. | See Table 5. Adjust the rebound and compression damping according to the motorcycle behavior experienced during the ride. | |
4. | After adjusting the suspension, ride the motorcycle again to check for comfort and response. NOTE When tuning the suspension, make all adjustments in small increments. Radical setting changes may overshoot the best adjustment setting. |
MOTORCYCLE BEHAVIOR | SUGGESTED REMEDY |
---|---|
Soft or unsettled feeling around corners or after bumps | Increase rebound damping |
Leaping feeling or topping after large bumps | Increase rebound damping |
Harsh/sharp feedback over bumps | Decrease rebound damping |
Feels like motorcycle drops down over chatter bumps | Decrease rebound damping |
Excessive bottoming through potholes | Increase compression damping |
Excessive dive when applying front brake | Increase compression damping (forks) |
Hard feeling or inadequate absorption over bumps | Decrease compression damping |
Feels excessively stiff or busy around corners | Decrease compression damping |
Item | Description (Quantity) | Part Number |
---|---|---|
1 | TORX® screw, self tapping, 3/8-16 x 1.5 in. (4) | 4352 |
2 | Front fork assembly, left | 48771-10 |
3 | Front fork assembly, right | 48778-10 |
4 | Shock absorber, left | 54671-10 |
5 | Shock absorber, right | 54700-10 |
6 | Amber reflector, right | 69861-07 |
7 | Amber reflector, left | 69862-07 |