Fork Removal and Installation

SAFETY FIRST: Protective gloves and eyewear are recommended at this point.

Removal

Remove the front wheel. See the Front Wheel topic for more information.

Remove the front fender. See the Front Fender topic for more information.

Remove the fork brace bolts with a 4 mm Allen.

Remove the fork brace.

Remove the clip-on handlebar bolt caps. Carefully pry the caps out with a pick or a small flat blade screwdriver.

Each clip-on handlebar is mounted to the upper fork clamp with a nut and bolt. Hold the nuts with a 14 mm wrench and loosen the bolts with an 8 mm Allen. The 750 models have a single handle bar holder piece for both bars that has four bolts.

Remove the nuts, bolts, and the clip-on handle bars. Support the bars so that they do not hang by the cables, wires, or brake hose.

Loosen the upper fork clamp pinch bolts with a 6 mm Allen.

If you plan to disassemble the forks go ahead and break the fork caps loose while the forks are being held in place by the lower fork clamp. Loosen the caps with a 24 mm socket. 

With a firm hold on the fork leg, loosen the four lower fork clamp pinch bolts with a 14 mm socket. Slide the forks down and out of the fork clamps using a twisting motion.

To disassemble the forks see the Front Fork Disassembly topic for more information.

Installation

Slide the fork legs up into the lower and upper fork clamps using a twisting motion.

Install the fork legs so that the top surface of the outer fork tube is flush with the top surface of the clip-on handlebar. The marks on the fork caps should align with the mars on the handlebars.

Torque the lower fork clamp bolts to specification with a 12 mm socket.

(Lower Fork Clamp Bolt Torque: 25 - 40 N-m or 18 - 29 lb-ft)

If the fork was disassembled tighten the fork caps to securely with a 24 mm socket.

Tighten the upper fork clamp pinch bolts to specification with a 12 mm socket.

(Upper Fork Clamp Bolt torque: 15 - 25 N-m or 11 - 18 lb-ft)

Install the clip-on handle bars.

Hold the nut with a 14 mm wrench and tighten the bolt to specification with an 8 mm Allen.

Insert the clip-on handlebar mounting bolt caps.

Install the front fender. See the Front Fender topic for more information. 

Install the front wheel. See the Front Wheel topic for more information.

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