Service Manual (KLZ1000C) — page 419 of 762

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SUSPENSION 13-27
Front Fork
Front Fork Assembly
• Replace the following parts with new one.
   Oil Seal [A]
     Outer Tube Guide Bushing [B]
     Inner Tube Guide Bushing [C]
     Dust Seal [D]
     Retaining Ring [E]
     Bottom Allen Bolt Gasket (Left Front Fork Only)
•   Install the following parts onto the inner tube.
     Dust Seal
     Retaining Ring
     Oil Seal
     Washer [F]
     Outer Tube Guide Bushing
     Inner Tube Guide Bushing

• Insert the inner tube to the outer tube.
• tube. new outer tube guide bushing [A] into the outer
  Fit the

                             NOTE
    ○When assembling the new outer tube guide bushing,
     hold the washer against the new outer tube guide bush-
     ing and tap the washer with the fork oil seal driver [B]
     until it stops.
    Special Tools - Fork Oil Seal Driver, 43: 57001-1530
                    or Fork Oil Seal Driver Weight, 26  46:
                       57001-1795
                    Fork Oil Seal Driver Attachment, 36  46:
                       57001-1798
• Install the oil seal by using the fork oil seal driver.
    Special Tools - Fork Oil Seal Driver, 43: 57001-1530
                    or Fork Oil Seal Driver Weight, 26  46:
                       57001-1795
                    Fork Oil Seal Driver Attachment, 36  46:
                       57001-1798
• Install the retaining ring and dust seal into the outer tube.
Right Front Fork
•Hold the inner tube lower end in a vise.
•Insert the cylinder unit into the inner tube.
•Replace the front fork bottom Allen bolt gasket with a new
 one.
•Apply non-permanent locking agent to the threads of the
 front fork bottom Allen bolt [A].
•Holding the cylinder unit with the fork cylinder wrench [B],
 and tighten the front fork bottom Allen bolt.
○Use a suitable arbor [C] to hold the special tool.
    Special Tool - Fork Cylinder Wrench: 57001-1875
    Torque - Front Fork Bottom Allen Bolt: 23 N·m (2.3 kgf·m,
                17 ft·lb)
• Pour in the specified type of oil (see Front Fork Oil
  Change(13-11)).