Front Install Order - Forks, Handlebars, Front tire

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tophog

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So I decided to tackle the 12K maintenance on the 2003 FJR1300 I just picked up with 12K miles. I had a bad fork seal so I removed those and they are at GP Suspension getting rebuilt with new springs. Got new tires installed and this evening I repacked the upper/lower steering head bearings. Now that I've got the handlebars, forks and front wheel off I started confusing myself on the assembly order once I get the forks back next week. I started thinking about this when I started to put the handlebars back on and realized it couldn't center it to bolt it down :)

Seems I will need to install forks first, handlebars then front wheel ?

 
The Service Manual has the correct order, But, you have it. If I remember correctly, there is also an order for tightening the fork pinch bolts, as well as the axle pinch bolts, The forks have to be in and tight before you torque the steering stem nut. Between the handle bars and the wheel, it doesn't make any difference.

 
Hello, Salem Oregon!

At first I thought you were trolling.

You're not, are you?

I'm sure you'll figure this one out -

hmmm...

:rolleyes:

 
Trolling? Why would you think that?

Look back in early 2007 ...there were a "few" threads on "2007 Altitude Surge Problem". I reported this problem on one of the very first 2007 bikes in the US ... and ended up selling it after 1500 miles because Yamaha or dealer thought I was nuts. Needless to say about 6 months later Yamaha finally confessed there was a problem and issued a ECU recall or something. I forget the details as I already had about 20K on a new 2007 BMW RT1200.

Not trolling ...

Hello, Salem Oregon!

At first I thought you were trolling.

You're not, are you?

I'm sure you'll figure this one out -

hmmm...

:rolleyes:
 
Last edited by a moderator:
Thanks. I have the service manual. Apparently I'm looking in the wrong section.

The Service Manual has the correct order, But, you have it. If I remember correctly, there is also an order for tightening the fork pinch bolts, as well as the axle pinch bolts, The forks have to be in and tight before you torque the steering stem nut. Between the handle bars and the wheel, it doesn't make any difference.
 
Curious about the proper sequence of tightening the pinch bolts and re-installation of the forks.

Mine are out at dealer being serviced and getting new fork tubes on both.

Don't have a service manual, however if you would post up the sequence for installing the forks,

it would be greatly appreciated.

Thanks.

 
OK, dealing with removal and re-installation of the forks starts on page 4-73 of the service manual. The process goes on for a number of pages as it concerns total servicing of the forks.

The manual calls for tightening the two lower bracket pinch bolts first and the doing the upper bracket pinch bolt. If you have received your forks back with the cap bolt already fastened, I suspect this really doesn't matter because it is the reverse of the removal procedure and the removal procedure has you leave the upper bracket pinch bolt tight so you can remove the cap bolt without putting the fork in a vice.

For what it's worth, I slide the fork leg in and hand tighten the upper bracket bolt to hold the fork in the position I want it in. Then I hand tighten the two lower pinch bolts. Then do the same to the other fork leg and check that both forks have the same reveal at the top. I like to place them so that the edge of the cap bolt is just above the bracket. Next, finagle your torque wrench onto the lower bolts and snug them to the proper spec (23Nm). With the forks held firmly, now would be the time to torque the cap bolts to 25Nm. Move up to the top bolts and snug them up to 25Nm. If you had removed the steering stem nut, torque it to 115Nm.

If you are also interested in the axle pinch bolts, read on. Looking from the front of the bike, the axle pinch bolts are numbered, right to left 1 through 4. The tightening sequence is 2-1-2, then 4-3-4. Tighten each bolt to 21Nm without temporary tightening. Normally, I go back and forth a couple of extra times so that the torque wrench clicks without any bolt movement.

Hope this was a help.

Dan

 
Good info. Apparently the manual doesn't call for mounting the front axle in the forks as part of "leveling/settling" the front forks to ensure there is no bind before tightening. I think I've read a few posts where people have done that but I'll stick to what's in the service procedure.

OK, dealing with removal and re-installation of the forks starts on page 4-73 of the service manual. The process goes on for a number of pages as it concerns total servicing of the forks.

The manual calls for tightening the two lower bracket pinch bolts first and the doing the upper bracket pinch bolt. If you have received your forks back with the cap bolt already fastened, I suspect this really doesn't matter because it is the reverse of the removal procedure and the removal procedure has you leave the upper bracket pinch bolt tight so you can remove the cap bolt without putting the fork in a vice.

For what it's worth, I slide the fork leg in and hand tighten the upper bracket bolt to hold the fork in the position I want it in. Then I hand tighten the two lower pinch bolts. Then do the same to the other fork leg and check that both forks have the same reveal at the top. I like to place them so that the edge of the cap bolt is just above the bracket. Next, finagle your torque wrench onto the lower bolts and snug them to the proper spec (23Nm). With the forks held firmly, now would be the time to torque the cap bolts to 25Nm. Move up to the top bolts and snug them up to 25Nm. If you had removed the steering stem nut, torque it to 115Nm.

If you are also interested in the axle pinch bolts, read on. Looking from the front of the bike, the axle pinch bolts are numbered, right to left 1 through 4. The tightening sequence is 2-1-2, then 4-3-4. Tighten each bolt to 21Nm without temporary tightening. Normally, I go back and forth a couple of extra times so that the torque wrench clicks without any bolt movement.

Hope this was a help.

Dan
 
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