Kawasaki KLE500 (2004) [278/401] Front fork oil level fully compressed without fork spring
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Kawasaki KLE500 (2004) [278/401] Front fork oil level fully compressed without fork spring

Kawasaki KLE500 (2004) [278/401] Front fork oil level fully compressed without fork spring
13-8 SUSPENSION
Front Fork
Front Fork Oil Change
•
Remove the front fork (see Front Fork Removal).
•
Remove the fork boot from the front fork.
•
Hold the outer tube vertically in a vise.
•
Remove:
Top Bolt [A] and O-ring [B]
Spacer [C]
Fork Spring Seat [D]
Fork Spring [E]
•
Pour out the fork oil [A] with the fork upside down.
•
Fill the front fork with the specified oil.
Fork Oil Viscosity: KAYABA KHL34-G10 or
equivalent
Fork Oil Capacity (when changing oil):
Approx. 453 mL (15.31 US oz.)
•
Wait for about five minutes so that any suspended air bub-
bles can surface.
•
Measure the oil level, using the fork oil level gauge [A].
Special Tool - Fork O il Level Gauge: 57001-1290
○
Set the gauge stopper [B] so that its lower side shows the
oil level distance specified [C].
○
Insert the gauge tube into the inner tube [D] and position
the stopper across the top of the inner tube [E].
○
Pull the handle slowly to draw out the excess oil until no
more oil comes up the tube.
If no oil is drawn out, there is not enough oil in the fork.
Pour in some more oil, then draw out the excess.
Front Fork Oil Level (Fully compressed without fork
spring)
Standard: 194 ±2 mm (7.64 ±0.08 in.)
•
Install the fork spring with the smaller diameter end [A]
facing down.
•
Install:
Fork Spring Seat
Spacer
•
Install the top bolt with a specified torque.
Torque - Front Fork Top Bolt: 30 N·m (3.1 kgf·m, 22 ft·lb)
•
Install the fork boot to the front fork.
•
Install the front fork (see Front Fork Installation).
•
Repeat the same procedure for another front fork.

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