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64
Front Forks
Tools recommended for front fork service:
•
Flat head screwdriver
•
Hammer
•
Pick
•
Seal driver MCMUTL02
•
9/16” (loose 14 mm) wrench
•
25mm wrench or socket
•
2.5 wt fork oil
FORK DISASSEMBLY PROCEDURES:
o
Using the 25mm wrench, remove the fork cap.
o
Drain the fork oil into a suitable container.
o
Disconnect the fork cap from the damper rod (9/16” wrench & 25mm wrench).
o
Disconnect the damper assembly from the fork leg by removing the large
aluminum bolt from the bottom of the fork leg (22mm wrench).
o
Pry the dust seal (swiper) from its position with a small screw driver.
o
Using a pick, remove the wire retaining ring holding the fork seals into place.
o
‘Pop’ the fork seal out by forcibly pulling on both ends of the fork tube
assembly, thus separating the inner from the outer tube.
o
Remove the bushings
o
Clean all components to be reused.
FORK ASSEMBLY PROCEDURES:
Figure 46
CAUTION:
Make sure all components are clean before assembly.
CAUTION:
Be sure to apply oil to the new fork seal and other components before installing.
1. Slide dust seal (swiper) (#6) onto lower fork leg.
2. Slide retaining ring (#5) onto lower fork leg.
3. CAREFULLY slide seal (#4) onto lower fork leg with spring facing away from
snap ring.