04 AXEL SERVICE MANUAL Page 14 REV NC
Bushing Installation (CONT.)
Bushing Installation Tool Assembly
With weighted handle
When selecting sizer rings to install bushings,
choose the two rings that are in the middle of
the size run to start with.
1. Assemble installation tool as shown in
picture above. Each leg diameter kit has all
of the needed pieces to remove and install
bushings for forks with serviceable
bushings. Some of the kits come with
gauges to tell you how far to drive in the
lower bushings. Upper bushings are driven
in as far as the stop in the top of the
casting will allow. The general rule of
thumb is that the lower bushings must not
be driven any deeper than 5” into a casting
leg. If they do go deeper, call Customer
Service at Answer Products – 800-423-
0273 for a new outer casting.
2. Always assemble Mandrel with the larger
diameter sizer ring being placed on the
mandrel first, then the spacer, the next
largest sizer ring, followed by the washer
and the nut to hold it in place. Be sure to
lock the nut above the Mandrel and below
the Mandrel against each other.
3. Replace the lower bushing (bushing with a
thicker wall diameter) first. Place a small
amount of Prep M grease onto the sizer
rings to help the rings come through the
bushings when pulling them out. Slide
bushing onto Mandrel until it stops. Apply
a bead of Red Loctite all the way around
the outside of the bushing. Hold casting on
top of bench with a rag under the end of
the legs and insert installation tool with
bushing into casting leg.
