11-12 SUSPENSION

Front Fork Separation Front Fork Assembly Notes

'Assembly is the reverse of disassembly.
eCheck the 0-ring at the top bplt Replace it with a
new one if damaged.
'Replace the removed oil sea' with a new one.
'Replace the guide bushes with new ones.
'Insert the cyiinder unit and spring in the inner tube.
•lnsert the cyiirder base in
cylinder unit

A. Inner Tube C. Cylinder Base

1. Inner Tube B. Cylinder Unit
2. Front Fork Outer Tube Weight: 57001 218
3. Outer Tube
4. Stroke
elnsert the inner and cylinder unit as a set into frie
outer
'Apply a liquid gasket to both sides of the gasket, and
apply a non-petmanent locking agent to the threads of
tae Allen bolt at the Inttom •of the outer tube.
'Stop tie cylinder from tuming by using the front fork
cylinder holder handle (special t": 57W1-183) and
'For the KX80 model; remove the outer tube sea[ holder adapter (special tool: 57W1-1257), tighten the
from the outer tube. Allen bolt to úe specified torque.
'For frae KXO rnodel; remove washer and outer
guide bush from the top of outer tube
'Remove the cylinder base from the bottom of the
outer tube.

Tightening Torque:
KX60, KDX80: -20 N-m (2.0 kg-m, 14.5 ft-lb)
KX80: 29 N-m (3.0 kg-m, 22 ft-lb)
B

eWhen replacing the outer -tui* guide bush with a

new one, hold the used guide bush against the new
one, and tap the used guide bush with the front
fork oil seal driver (special t") until it stops. The
slit in the bush must face toward the wheel.

A. Outer Tube B. Cylinder Base