RX3 Fork Seal/Oil Service
Tools required:
- 5mm Allen
- 6mm Allen
- 37mm Fork Seal Tool
- 14mm, 16mm, 19mm Wrenches
- 8mm, 12mm, 19mm Sockets
- Electrical Tape
- Flathead Screwdriver
- Fork Oil
- Fork Seals
Use 5mm Allen to remove the plastic cover from the top of the ignition switch.
Use 6mm Allen to loosen the upper triple tree fork clamp.
*Tip: it is easier to loosen the fork cap while the fork is still mounted on the motorcycle. Do not remove the cap at this point (only loosen it).
Lift the front end off the ground.
Use a 5mm Allen to remove the fork guards.
Use a 19mm socket to remove the axle nut.
Use an 8mm socket to remove the ABS sensor.
Use a 5mm Allen and an 8mm socket to remove the front fender.
Use a 12mm socket to remove the brake caliper.
Use a 12mm socket to remove the axle pinch bolts.
Remove the axle.
Use a 6mm Allen to loosen the lower triple tree fork clamp.
Gently and firmly twist the fork and pull down out of the clamps.
Use a 19mm socket to loosen the fork cap.
Empty the fork oil.
Use a 14mm and 16mm wrench to loosen the fork cap nut.
Remove the cap/needle assembly and spring.
Use a flathead screwdriver to gently remove the dust seal.
Use a flathead screwdriver to remove the retaining clip.
Slide off the fork leg.
Remove the small retaining ring.
Remove the large retaining ring.
Remove the washer.
Remove the fork oil seal.
Remove the dust seal.
Thoroughly clean the fork tube and apply electrical tape to it.
The electrical tape will cover the sharp edge of the tube and protect the new seals upon installation. Install the dust seal.
Install the fork oil seal. (*Note: the larger spring side of the fork oil seal faces the top of the fork)
Install the washer.
Install the large retaining ring.
Install the small retaining ring.
Install the fork leg.
Use a 37mm fork seal tool to install the fork oil seal.
Install the retaining clip.
Securely seat the retaining clip with a flathead screwdriver.
Use the back of the screwdriver handle to tap in the dust seal.
Install the spring.
A magnet can be used to pull the threaded rod above the spring for easier access when screwing on the cap/needle assembly.
Install the cap/needle assembly.
Use a flathead screwdriver to push the rod to the bottom of the cap to help get the threading started.
Use a 14mm and a 16mm wrench to securely fasten the cap/needle assembly.
Add 11.2oz (approx. 330cc) of fork oil.
Use a 19mm wrench to screw on the cap.
Install the fork. Use a 6mm Allen to tighten the triple tree fork clamps.
Install the front fender.
Use an 8mm socket to install the ABS sensor.
Install the fork guard.
Once the fork clamps are tightened securely the place the final tighten on the cap.
Repeat the process for the right fork.
After both forks have been serviced reinstall the axle.
Use a 19mm socket to tighten the axle nut to 40-45 foot pounds.
Use a 12mm socket to tighten the axle pinch bolts to 20 foot pounds.