Honda NSS250A Reflex 2001-2007, Manual

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FRONT WHEEL/SUSPENSION/STEERING
15-24
Do not over-tighten
the bottom case.
Hold the bottom case in a vise with a soft jaws or
shop towel.
Clean the socket bolt threads and apply locking
agent to the socket bolt threads.
Install the socket bolt with a new sealing washer
into the fork piston.
Tighten the fork socket bolt to the specified torque.
• If the fork piston turns together with the socket
bolt, temporarily install the fork spring and fork
cap bolt.
Install the guide bushing and buck up ring over the
fork pipe and set them on the bottom case.
Coat a new fork oil seal lips with fork fluid and
install it onto the fork pipe with marked side facing
up.
Install the fork oil seal into the bottom case until the
stopper ring groove appear using special tools.
Install the stopper ring into the groove in the bot-
tom case, being careful not to scratch the fork pipe.
Coat a new dust seal lips with fork fluid and install it
into the bottom case.
Pour the specified amount of recommended fork
fluid in the fork pipe.
Slowly pump the fork pipe several times to remove
trapped air.
Compress the fork pipe fully and measure the oil
level from the top of the fork pipe.
TORQUE: 29.4 N·m (3.0 kgf·m, 22 lbf·ft)
SEALING WASHER
SOCKET BOLTS
TOOLS:
Fork seal driver body
07747-0010100
Fork seal driver attachment, 35.2 mm
07947-KA20200
DRIVER BODY
ATTACHMENT GUIDE BUSHING
BACK UP RING
OIL SEAL
STOPPER RING DUST SEAL
RECOMMENDED FORK FLUID:
Honda Ultra Cushion Oil 10 W or equivalent
FORK FLUID CAPACITY:
204
±
2.5 cm
3
(6.9
±
0.08 US oz, 7.2
±
0.09 Imp oz)
Be sure the oil
capacity is the
same in both fork
legs.
FORK OIL LEVEL: 90 mm (3.5 in)
90 mm
(3.5 in)
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