HOME ASSEMBLY 3. See Figure 2-125 . Using FRONT FORK TUBE HOLDER (Part No. HD-41177), mount fork assembly in vise. TOOL NAME PART NUMBER FORK SEAL DRIVER B-42571 4. Make sure cap (centering plate) is on bottom end of fork cartridge and install fork cartridge (big end first) into fork slider. FRONT FORK TUBE HOLDER HD-41177 FRONT FORK COMPRESSOR HD-45966 5. Remove fork and fork tube holder from vise. INNER FORK NUT REMOVER/INSTALLER HD-47852 OIL LEVEL GAUGE HD-59000B sm03139 Left Side NOTE Chamfered lips on oil seal MUST face towards oil in fork. 1. See Figure 2-124 . Use sleeve from fork seal driver and install chrome dust cover (not shown) and components onto fork slider in order shown.
sm03142 1 2 3 4 5 Figure 2-126. Install Fastener and Copper Washer NOTE Always use soft jaws for bench vise when placing any fork components into vise to prevent damage to components. 6. See Figure 2-126 . Using a vise with soft jaws, clamp fork slider in vise. Install new fastener and copper washer to hold fork cartridge in place inside fork tube.Tighten to 15- 25 Nm (132-221 in-lbs ). 1. Bushing 2. Spacer 3. Fork seal (chamfered lips must face oil) 4. Lock ring 5. Dust seal 7. Reposition fork in vise using FRONT FORK TUBE HOLDER (Part No. HD-41177), secure fork assembly in vise. Figure 2-124. Fork Tube Shown Installed In Order of Installation 8. See Figure 2-127 .
Assemble FORK SEAL DRIVER (Part No. B-42571) over fork slider in front of oil seal with the long end of tool facing seal. Install parts in the following order: bushing, spacer, and drive fork seal into fork tube bore with tool until tool is flush with fork slider. 2. Lightly coat fork slider and bushing with fork oil and gently install slider into fork tube. 9. Install lock ring into groove in top of oil seal. Verify lock ring is properly seated. sm03148 1 sm03149 2 1. Fork cartridge 2. Fork tube Figure 2-125. Install Fork Cartridge Figure 2-127. Install Bushing, Spacer, and Install Fork Seal in Place with Seal Driver 2009 VRSC Service: Chassis 2-93 . Install Fork Cartridge Figure 2-127.
Install Bushing, Spa in Place with Sea 2009 VRSC 1. Fork cartridge 2. Fork tube Figure 2-125 cer, and Install Fork Seal l Driver Service: Chassis 2-93