Special Tools

Description	Part Number	Qty.
FORK TUBE HOLDER	HD-41177	1
FRONT FORK COMPRESSOR	HD-45966	1

Initial Disassembly

1.	See Figure 1. Clamp fork tube (2) in fork tube holder (1). Mount in vise with fork vertical. Special Tool: FORK TUBE HOLDER (HD-41177) NOTE Record preload, compression and rebound settings.
2.	Turn preload adjuster fully counterclockwise. See the owner's 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)

NOTE

Have a suitable container ready to place components into after removal from tube.

3.	See Chassis → FRONT FORK → Assemble → Front Fork Components. Remove fork tube cap. a. Separate fork tube cap (1) from fork tube (11). b. Compress fork assembly. c. See Figure 2. Clamp front fork compressor vertically in vise with length adjuster screw topside. Special Tool: FRONT FORK COMPRESSOR (HD-45966) d. Hold fork tube cap and compress spring enough to access hex nut (1). e. Loosen hex nut. f. Remove fork tube cap.
4.	Remove front fork compressor.
5.	See Chassis → FRONT FORK → Assemble → Front Fork Components. Remove and discard O-ring (2).
6.	Remove spring seat stop (3).
7.	Remove seal (5).
8.	Remove spring. a. Remove spring collar (6). b. Remove spring joint (7). c. Remove spring (10).

1	Fork tube holder
2	Fork tube

Figure 1. Fork Tube Holder

Nut

Figure 2. Compress Fork Spring

Drain Fork Oil

NOTE

Drain fork oil into a suitable container.

1.	Drain fork oil. a. Thread rod extension tool (part of front fork compressor) onto end of damper rod. Special Tool: FRONT FORK COMPRESSOR (HD-45966) b. Turn fork assembly upside down over drain pan and slowly pump damper rod at least 20 times until rod moves freely.
2.	Remove extension tool from damper.

Complete Disassembly

1.	See Chassis → FRONT FORK → Assemble → Front Fork Components. Remove damper. a. Remove screw (19). Use an air impact wrench for best results. Discard screw. b. Remove damper (8). c. Remove centering plate (9).
2.	Separate fork tube from fork slider. a. Remove dust seal (17). b. Remove retaining ring (16) from groove inside fork tube (11). c. Expand fork slider (18) and fork tube against each other repeatedly (in a slide hammer effect) to remove fork tube.
3.	Disassemble fork slider. a. Remove slider bushing (12). b. Remove guide bushing (13). c. Remove seal spacer (14). d. Remove and discard oil seal (15). e. Remove retaining ring (16). f. Remove dust seal (17).

Clean and Inspect

1.	Clean all parts.
2.	Inspect parts for wear or damage. Replace parts as necessary.
3.	Inspect OD of slider bushing and ID of fork tube bushing. a. If coating is worn through (metallic substrate showing), replace bushing. b. Inspect for distortion. c. If deep scratches or scoring are found, replace bushing. Also inspect mating components for similar wear. Repair or replace as necessary.
4.	Check fork tube and fork slider for scoring, scratches and abnormal wear.
5.	Inspect slider tube for nicks from stones and road debris, especially in area where seal contacts it. Replace if necessary.
6.	See Figure 3. Check runout with a dial indicator. a. Set fork slider on V-blocks. b. Replace fork if runout exceeds: Dimension: 0.2 mm (0.008 in)

Figure 3. Measure Fork Tube Runout