04 AXEL SERVICE MANUAL Page 6 REV NC
2004 Axel Forks Disassembly and Rebuild Instructions
Disassembly Instructions
Removal of Outer Casting
1. From the left leg dropout (Left when sitting on the bike), use a 4mm hex wrench to
remove the compression rod screw.
2. From the right leg dropout, if the fork has adjustable rebound, the knob will need to be
removed. Remove the 2mm hex screw inside the knob and remove the knob.
3. Use a 8mm hex wrench to turn the damper
clockwise
until it can be pushed into the
casting.
4. Remove crown/steer/inner leg assembly from the outer leg casting.
Bushing Removal & Installation
Please refer to section on Bushing Removal & Installation.
Removal of Spring
and Compression Rod Assembly - Non-Wind Down Travel
Adjust Forks
WARNING
This fork uses a preloaded coil spring provide spring resistance. The spring
must be relieved of its preload prior to servicing. Failure to do so could result in injury or
possible death.
1. Turn spring preload adjuster knob counter clockwise until it stops. Remove 2mm hex
screw on spring preload adjuster knob and remove knob on the top left side of the fork.
2. Remove preload adjuster using 18mm socket.
3. Compress fork and remove the spring preload and spring assy.
4. Remove rubber bumper and clip on compression rod.
5. Turn crown/steer upside down to allow the comp rods to fall out of the inner legs.
Removal of Spring
and Compression Rod Assembly - Wind Down Travel Adjust
Forks
1. Turn travel adjust knob (clear plastic knob on top of the left side of the crown) in a
counterclockwise direction until it stops. This insures that the fork is in its longest travel
and reduces any spring preload on the fork.
2. Remove the 2mm Allen screw from the knob. Use a 28mm socket to unscrew the top cap
assembly from the crown.
3. Pull spring out of inner leg. If spring will not come out, you must take the outer casting off
of inner legs (refer to Removal of Outer Casting instructions). Then remove the end cap
from the bottom of the left leg and remove the Wind Down compression rod assembly
and spring as a single unit through the bottom of the leg. You will find that on earlier
production fork models, that there is a nylon washer at the top of the compression rod
assembly that is holding the spring in place. Hold the spring in one hand and the
compression rod assembly in your other hand and pull the apart from each other at a
slight angle to each other. Once you have the two apart, remove the Allen bolt on top of
the compression rod with a 4mm Allen wrench and remove the nylon washer (Fig 2). Re-
install the bolt without the washer, it will not affect the operation of the Wind Down
mechanism and insure that you will not have to take the whole fork apart in the future to
change ride kit springs. (Note: the spring that you remove should have another spring
(booster spring) intertwined within it)
