HOME NOTE To prevent cross threading fork tube damper cups and caps, use caution when threading in the caps with the spring com- pressed. It may be helpful to use a palm-ratchet during this process. 17. See Figure 2-133 . Apply a light coat of fork oil on o-ring and thread cap into fork tube. Thread fork cap into fork and tighten to 29-39 Nm (21.3-28.8 ft-lbs). INSTALLATION 14. See Figure 2-140 . Final tighten inner fork nut to 93-113 Nm (69-83 ft-lbs) using INNER FORK NUT REMOVER/INSTALLER (Part No. HD-47852). TOOL NAME PART NUMBER TRIPLE TREE WEDGE TOOL HD-48287 Use new fork pinch bolts (P/N 4534M). Tap bolt holes and blow bolt hole threads clean with compressed air.
sm03159 • Any time fork pinch bolts are loosened or removed for any reason, follow this recommended procedure for proper installation. NOTES • Replace loosened or removed fork pinch bolts with new fork pinch bolts (P/N 4534M). Tap triple clamp bolt holes with a bottoming tap and blow holes clear with compressed air to remove excess lockpatch material. • Fork tube depth measurement is critical and must match the opposite side exactly to verify proper vehicle operation, reliability and performance. • When installing fork leg from triple trees, do not twist fork leg to avoid damage to cosmetic finishes. 1. Identify left and right side fork assemblies. 2.
Insert fork assembly from the bottom triple clamp upward through the top triple clamp. Figure 2-140. Hand Tighten 3. 48287) installed in triple clamp clamps during removal process. 15. See Figure 2-141 . Install rubber stopper, followed by retainer nut (retainer nut must be installed 14 mm (0.551 in) from top of threaded shaft). NOTE Fork tube protrusion should be measured at the top of the upper triple clamp surface where the handle bars bolt to triple TRIPLE T REE WEDGE TOOL (Part No. HD- clamp. sm05753 4. See Figure 2-142. Measure pr triple clamp (2) to top of fork 3 must be exactly the same and in). 2 1 1. Rubber stopper 2. Retainer nut 3. Fork cap Figure 2-141.
Install Rubber Stopper, Retaining Nut, and Fork Cap 16. Thread fork cap onto fork and tighten fork cap against retainer nut to 17.5-22.5 Nm (154-199 in-lbs.). 2009 VRSC clamp. 4. See Figure 2-142. Measure pr triple clamp (2) to top of fork must be exactly the same and in). bber Stopper, Retaining Nut, and Fork Cap o fork and tighten fork cap against 2.5 Nm (154-199 in-lbs.). 2009 VRSC Figure 2-141. Install Ru 16. Thread fork cap ont retainer nut to 17.5-2 17.5-2 2.5 Nm