SAFETY FIRST: Protective gloves and eyewear are recommended at this point.
Apply fork oil to the dust seal and oil seal lip before installing.
Cover the fork tube with plastic wrap, then install the dust seal, stopper ring and the oil seal in that order. The plastic wrap will help from damaging the lip of the oil seal when installing it onto the fork tube.
NOTE: The markings on the oil seal should face the dust seal.
Remove the plastic wrap and install the fork seal retainer, guide bushing and the slide bushing in that order.
NOTE: After installing the bushings, inspect for cracks in the Teflon, if damaged replace them.
Install the forks inner components.
Before installing the inner tube into the outer tube, lube the bushings with fork oil. Carefully insert the inner tube into the outer tube.
Use a damper rod holding tool to keep the damper rod from turning, install the damper rod Allen bolt and torque it to specification.
damper bolt torque: 39 N-m or 29 ft-lb
The damper rod holding tool is part number DS-TOOL25.
Drive the slide bushing in using a fork seal driver. Make sure it seats correctly before installing the oil seal.
Install the oil seal using a fork seal driver. Once the seal retainer clip groove can be seen, the oil seal is fully seated. If a fork seal driver tool is not available, you can use a piece of PVC tubing as shown above. Cut it down the middle and place the two halves onto the fork oil seal, and drive the oil seal into place. To keep the two pieces from moving, you can use a hose clamp or a zip tie around them.
Install the fork seal retainer clip into its groove and make sure its fully seated.
Install the correct amount of Kayaba G10 fork oil or an equivalent.
fork oil capacity after rebuild is 420 ± 4 mL or 14.0 to 14.3 US oz.)
Install the fork cap bolt and tighten it and the fork pinch bolts to their proper torque specification after installing the forks into the triple tree.
fork cap bolt torque: 29 N-m or 22 ft-lb
upper and lower triple clamp pinch bolts is 25 N-m or 18 ft-lb
Install the front wheel. See the Front Wheel Installation topic for more information.
Install the front brake caliper. See the Front Brake Pad Replacement topic for more information.