Chapter 7 The
on models
119
5 Remove the damper rod Allen bolt. If this has broken free
from the lower leg but will not unscrew from the damper rod,
obtain a piece of hardwood dowel of the same length and
diameter as the fork spring(s) and grind a coarse taper on one
end. Compress the stanchion fully into the lower leg and insert
the dowel into the stanchion so that its tapered end engages
with the head of the damper rod. Either rest the dowel outer end
against a solid object so that the maximum pressure can be
applied to lock the damper rod, clamp it in a vice, or clamp a
self-locking wrench on to it so that an assistant can apply
pressure and prevent rotation at the same time.
6 Remove the stanchion from the lower leg and invert it to tip
out the damper rod and rebound spring, then invert the lower
leg to tip out the damper rod seat. The oil seal can be prised out
of the lower leg using a large
screwdriver which has
had any sharp edges ground off; be very careful not to damage
the top edge or to scratch the seal housing when using this
method. Do not apply excessive pressure; if the seal proves
difficult to remove, pour boiling water over the outside of the
lower leg to expand the alloy sufficiently to release its grip on
the seal.
7 All components can be checked for wear and renewed if
necessary following the general instructions given in Chapter 4.
If the damping action has deteriorated renew the damper rod
piston ring and be very careful to clean all components.
Fig. 7.3 Front forks
/
2
3
4
5
6
7
Right-hand fork leg
Right-hand headlamp bracket
Guide - 4 off
Left-hand headlamp bracket
Left-hand fork leg
Top bolt
8 Fork spring
9 Piston ring
10 Damper rod
Rebound spring
12 Stanchion
13 Dust seal
lip
15
seal
Damper rod seat
17 Lower leg
18 Sealing washer
19
bolt
