Husqvarna 2009 TE 250, Workshop Manual

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I.7
Part. N. 8000 H0368 (09-2008)
FRONT SUSPENSION
GENERAL RULES FOR A PROPER OVERHAULING
• After a complete breakdown, always use new, original Marzocchi seals when reassembling.
• To tighten two bolts or nuts that are near each other, always follow the sequence 1- 2- 1 using a torque wrench; respect the indicated
tightening torques (see Table 1 - Tightening Torques).
• Never use flammable or corrosive solvents to clean the parts, as these could damage the seals. If necessary use specific detergents
that are not corrosive, not flammable or have a high flash point, compatible with the seals materials and preferably biodegradable.
• Before reassembling, always lubricate the parts of the fork in contact.
• If you are planning not to use your fork for a long time, always lubricate the forks components that are in contact with some fork’s oil.
• Never pour lubricants, solvents or detergents which are not completely biodegradable in the environment; these must be collected and
kept in the relevant special containers, then disposed of according to the regulations in force.
• Always grease the seals lips before reassembling.
• Use only metric spanners, not imperial spanners, which may have similar sizes, but can damage the bolts and make it impossible to
unscrew them.
• Use the correct size and sort of screwdriver to unscrew slotted or crosshead screws.
• When using a screwdriver to assemble or disassemble metal stop rings, o- rings, sliding bushings or seal segments, avoid scratching
or cutting the components with the screwdriver tip.
• Only proceed to maintenance/ overhaul operations if you are sure you are able to do it and you have got the right tools to do so. If this
is not the case, or if you are unsure, please contact an authorized service center, where specialized technicians with the right tools and
original spare parts will service and overhaul your fork, putting it back into its original working conditions.
• Only use original spare parts.
• Before servicing/ overhauling make sure you have all the spare parts you need for the complete overhaul of both the fork legs (n° 2 oil
seals, n° 2 dust seals, n° 2 piston segments).
• Work in a clean, ordered and well- lit place; if possible, avoid servicing outdoors.
• Before servicing the fork, we recommend washing the motorcycle thoroughly and in particular washing the fork well.
• Carefully check there are no metal shavings or dust in the work area.
• We recommend overhauling one fork leg at a time.
• Do not modify the components of the fork.
INSTRUCTIONS FOR CLAMPING IN THE VICE
For some maintenance procedures you may have to use the vice to clamp some
components of the fork.
WARNING
The incorrect use of the vice can cause irreparable damage to the fork.
Scrupulously follow the instructions below:
• Limit the use of the vice to those operations where the use of the same is absolutely
necessary;
• Use a vice with padded jaws;
• Avoid over tightening the vice;
• Avoid clamping parts of the fork where even slight ovalization could damage the
part;
The figure shows the zones recommended for fixing the fork in the vice.
A - Wheel axle clamp
B - Slider in the steering crown fixing zone
C - Top part of pumping element rod above the seat of the spring guide stop ring.
D - Bottom valve spanner seizing
C
B
A
D