13-8 SUSPENSION

Front Fork
Front Fork Removal (each fork leg)
• Loosen
ter)
the front wheel axle nut (see wheels/Tires chap-

• Raise the front wheel off the ground.

Special Tools - Jack: 57001-1238
Jack Attachment #3: 57001-1416
• Remove:
Caliper (for left fork only) (see Wheels/Tires chapter)
Front Fender (see Frame chapter)
Front Fork Upper Clamp Bolt [A]
Front Fork Lower Clamp Bolt [B]
• With a twisting motion, work the fork leg down and out.
NOTE
If the fork is tight, tap lightly around the base of the stem
head with a plastic mallet.

Front Fork Installation

• For VN800-B8 model, note the following procedure.
Install the spacer [A] so that the distance between the
fork top end [B] and the upper surface [C] of the spacer is
249.6 mm (9.83 in.) [D].
Torque - Spacer Allen Bolt: 4.4 N·m (0.45 kgf·m, 39 in·lb)
Insert the washer, rubber seat and fork lower cover to the
inner tube.

• Turn the clamp bolt (lower) clockwise posing the fork leg
upward fully.
• Install the fork so that the top end [A] of the inner tube is
flush with the upper surface of the steering stem head.
• Tighten:
Torque - Front Fork Clamp Bolt (Lower): 34 N·m (3.5 kgf·m,
25 ft·lb)
Front Fork Clamp Bolt (Upper): 20 N·m (2.0 kgf·m,
14.5 ft·lb)
• Install the removed parts (see appropriate chapters).
Fork Oil Change
• Refer to the Front Fork Oil Change in the Periodic Main-
tenance chapter.
 SUSPENSION 13-9
Front Fork
Front Fork Disassembly
• Remove the front fork (see Front Fork Removal).
• Drain the fork oil (see Fork Oil Change in the Periodic
Maintenance chapter).
• Tap the point [A] with a suitable tool to separate the dust
seal cover [B] from the outer tube [C].

• Hold the front fork horizontally in a vise [A].

• tools. cylinder unit [B] from turning by using the special
Stop the

• Unscrew the Allen bolt [C], and take the gasket out of the
bottom of the outer tube.
Special Tool - Fork Cylinder Holder Handle: 57001-183 [D]
Fork Cylinder Holder Adapter: 57001-1057
[E]
• Take the cylinder unit out of the inner tube.
• Remove the cylinder unit [A] and short spring [B] from the
inner tube.

• Separate the inner tube from the outer tube as follows:

Slide up the dust seal [A].
Remove the retaining ring [B] from the outer tube.

Grasp the inner tube and stroke the outer tube up and
down several times. The shock to the fork seal separates
the inner tube from the outer tube.
If the tubes are tight, use a fork outer tube weight [A].
Special Tool - Fork Outer Tube Weight: 57001-1218
13-10 SUSPENSION
Front Fork

• Remove the inner tube guide bushing [A], outer tube

guide bushing [B], washer [C] and oil seal [D] from the
inner tube.
• Remove
tube.
the cylinder base from the bottom of the outer

Front Fork Assembly

• Replace the following parts with new one.
Oil Seal
Guide Bushings
Bottom Allen Bolt Gasket
• Install the following parts onto the inner tube.
Dust Seal
Retaining Ring
Oil Seal
Washer
Outer Tube Guide Bushing
Inner Tube Guide Bushing

• Insert the cylinder unit [A] into the inner tube [B].
• Insert the
Install the cylinder base [C] on the cylinder unit.
• into the outer
inner tube, cylinder unit, cylinder base as a set
tube [D].
• Stop the cylinder from
Replace the bottom Allen bolt gasket with a new one.
• holder. turning by using the fork cylinder

Special Tool - Fork Cylinder Holder Handle: 57001-183

Fork Cylinder Holder Adapter: 57001-1057
• Apply a non-permanent locking agent to the Allen bolt and
tighten it.
Torque - Front Fork Bottom Allen Bolt: 20 N·m (2.0 kgf·m,
14.5 ft·lb)

• Fit the new outer guide bushing [A] into the outer tube.
NOTE
When assembling the new outer tube guide bushing,
hold the used guide bushing [B] against the new bush-
ing and tap the used guide bushing with the fork oil seal
driver [C] until it stops.
Special Tool - Front Fork Oil Seal Driver: 57001-1219
• After installing the washer, install the oil seal by using the
fork oil seal driver.
• Install the retaining ring and dust seal by hand.
 SUSPENSION 13-11
Front Fork

• Face the notch [A] of the dust seal cover rearward [B] and
install the dust seal cover by tapping with the fork outer
tube weight [C] until it stops.
Special Tool - Fork Outer Tube Weight: 57001-1218

• Stake [A] the dust seal cover with a punch.

• For VN800-B8 model, note the following procedure.

Install the spacer [A] (see Front Fork Installation).
Insert:
Washer [B]
Rubber Seat [C]
Lower Cover [D]

• Poor in the specified type and amount of oil (see the Front
Fork Oil Change in the Periodic Maintenance chapter).
• Install the fork leg (see Front Fork Installation).
13-12 SUSPENSION
Front Fork
Inner Tube Inspection
• Visually inspect the inner tube, and repair any damage.
• Nicks or rust damage can sometimes be repaired by using
a wet-stone to remove sharp edges or raised areas which
cause seal damage.
If the damage is not repairable, replace the inner tube.
Since damage to the inner tube damages the oil seal,
replace the oil seal whenever the inner tube is repaired
or replaced.
CAUTION
If the inner tube is badly bent or creased, replace
it. Excessive bending, followed by subsequent
straightening, can weaken the inner tube.

• Temporarily assemble the inner and outer tubes, and

pump them back and forth manually to check for smooth
operation.
• If you feel binding or catching, the inner and outer tubes
must be replaced.
WARNING
A straightened inner or outer fork tube may fall in
use, possibly causing an accident. Replace a badly
bent or damaged inner or outer tube and inspect the
other tube carefully before reusing it.

Dust Seal Inspection

• Inspect
damage.
the dust seal [A] for any signs of deterioration or

Replace it if necessary.

Spring Tension
• Since a spring becomes shorter as it weakens, check its
free length [A] to determine its condition.
If the spring of either fork leg is shorter than the service
limit, it must be replaced. If the length of a replacement
spring and that of the remaining spring vary greatly, the
remaining spring should also be replaced in order to keep
the fork legs balanced for motorcycle stability.
Fork Spring Free Length
Standard: 547.2 mm (21.54 in.)
Service Limit: 536 mm (21.1 in.)