HOME 2.32 FRONT FORK: ALL EXCEPT VRSCF REMOVAL 1. Support motorcycle so front end is off floor and forks are fully extended. sm03229 2. Remove right side cover and maxi-fuse. See 7.4 MAXI- FUSE . 3. Remove air box cover. See 1.5 AIR CLEANER AND EXHAUST SYSTEM . 4. Remove negative battery cable. 5. Remove both front brake calipers. See 2.16 FRONT BRAKE CALIPER . 6. Remove front wheel. See 2.23 FRONT WHEEL . 7. Remove front fender bracket with the front fender. See 2.31 FRONT FENDER . 8. See Figure 2-103 . On one side, first loosen pinch bolt (2) on top triple clamp (25). 9. Break loose but do not remove fork tube cap (22). 10.
Loosen pinch bolts (2) on bottom triple clamp (24) and pull fork tube and slider assembly (26) from triple clamp. Figure 2-100. Fork Holding Tool (mounted vertically to slider) 11. Repeat procedure for opposite fork tube and slider assembly (27). 6. Clamp fork tube in holder. Mount FORK TUBE HOLDER (Part No. HD-41177) horizontally in vise. 7. Remove slider cover (7) from slider by inserting brass drift into notch in slider and lightly tapping cover. 8. Compress stopper ring (16) and remove stopper ring from groove in top of slider bore. 1. See Figure 2-100 . Clamp fork tube and slider assembly in FORK TUBE HOLDER (Part No. HD-41177) and mount in vise.
NOTE The VRSC models have a preloaded fork spring.The seat pipe is under spring pressure. Always wear proper eye protection when disassembling the fork tube and slider assembly. Disas- semble the fork tube and slider assemblies carefully. The springs can force parts from the fork tube or slider unexpec- tedly, which could result in death or serious injury. 2. See Figure 2-103 . While internal components are still under tension and less prone to rotate, break loose but do not completely unthread screw (1). On right fork tube and slider assembly, remove axle holder (6) to access seat pipe screw. 9. Remove screw (1) and lockwasher (5) from bottom of slider (10). Retain the screw and washer.
Wear safety glasses or goggles when servicing fork assembly. Do not remove slider tube caps without relieving spring preload or caps and springs can fly out, which could result in death or serious injury. (00297a) 10. Withdraw slider (10) from slider tube (9) until bushing guide (19) contacts slider bushing (28) on fork tube. Bushing guide is a slight interference fit in slider. 11. Using the slider as a slide hammer, hit the bushing with the bushing guide with a quick continuous stroke until slider is pulled free of the fork tube. 3. Remove slider tube cap (22) and O-ring (11). 4. Remove the long spring collar (13). 5. Remove from FORK TUBE HOLDER and invert fork over a suitable container.
Allow fork to drain. Extend and retract slider several times to push oil out of internal components. The washer (12), and spring (14) will fall out of fork tube. 12. Drain the slider and allow the stop oil lock piece (21) to fall free. NOTE If replacing the slider only, the components remaining in the fork tube can be left assembled and the fork re-assembled from ASSEMBLY procedures step 5. 13. If still attached to seat pipe, remove stop oil lock piece from the lower end of seat pipe. 14. Remove seat pipe (23) piston and ring assembly. 2009 VRSC Service: Chassis 2-81 DISASSEMBLY PART NUMBER TOOL NAME HD-41177 FORK TUBE HOLDER (Part No. HD-41177)