Front Fork Service Guide The following fork service was carried out on a 2010 ABS Fireblade but the process is very similar for all USD forks but some forks may have very slight differences which are common with the exception of the BPF forks which are completly different. Double check if your forks have any construction differences by checking with a service manual for your bikes make/model. Disclosure: I take no responsibility for any damage or injury caused by using the information contained within this guide. If you do not agree with and accept the above terms please do not use any of the information which follows and have your forks serviced by a qualified suspension technician. Tools you will need and/or find useful in order to carry out the fork service:- • Correct grade fork oil 1 litre will be enough for both forks with a small amount left over. • Fork oil seals and dust seals if yours are old, splitting & cracking or leaking - I tend to replace both while I have the fork stripped down that far. • Fork seal driver or a piece of PVC pipe cut in half if trying to keep costs down! • Fork spring compressor – large commercial or handheld DIY type (this type may also require a friend to help fit compressor plate!) • Steel rule - A fork oil level tool is also handy but not required. • Fork rod pull up tool - Handy but not a requirement! • Motorbike stands front and rear - front stand must be capable of lifting front end off the ground but leave forks unloaded so they can be safely removed, i.e. Headstock stand, Abba superbike stand or something similar. • Front axle tool – required in order to be able to remove the front wheel. • Basic hand tools such as Allen keys, rubber mallet, sockets and spanners which will be required to remove various parts from the bike. • Lots and lots of paper towels to clean everything as it gets pretty messy with oil. • Latex or nitrile gloves to protect hands from oil. • Metal polish and cloth – this is not required but I do recommend using it to reduce sticktion. • Electrical tape. Step 1. Start off by putting the bike up on paddock stands. Removing the fairings will allow better access to the bolts on the lower yoke but not required. Step 2. Slacken off the 2 Allen bolts at the top of each fork. Step 3. With all the top yoke bolts now slackened, slightly slacken off both top fork caps so it’s easier to strip the forks down later once removed from the bike. Paper towel sheets folded up on themselves can help limit any coating damage caused to the caps and/or bolt heads while loosening them. Step 4. Remove the 2 caliper retaining bolts on each front caliper and slide each caliper off the discs. Use bungee cords or tie wraps to tie up the calipers up to make sure they are not hanging by their brake lines as this can damage them.