Damping System (Right Leg) Service – Leg Removal
(Figure 9)
It is recommended that the
right leg be removed before
service. Remove inner leg from
outer leg as follows:
1.
Pull the rebound damper
adjuster knob (1) out of
the damper nut.
2.
Remove the damper nut
(2) with an 8 mm hex
wrench.
3.
Pull the inner leg (3) out
of the outer leg (4).
4.
Remove the leg guard.
Damping System (Right Leg) Service – Leg Disassembly
(Figure 10)
Oil is removed from the
inner leg (3) by removing
the rebound and com-
pression assemblies to
ensure that all old oil is
removed from the sys-
tem. The compression
damping assembly (2) is
located at the bottom
(dropout) end and the
rebound assembly (1) is at the top.
1.
Rebound Assembly Removal – With the rebound assembly end of
the leg pointing up (to minimize spilling damping oil), unscrew
the end cap and slowly pull out the assembly over a drip pan.
Pour out and discard the damping oil.
2.
Compression Damping Assembly Removal – Unscrew the screw
holding the adjuster knob and remove the knob. Loosen the 13
mm adjuster needle lock nut (Figure 11, #1). Unscrew the end
cap using a 20 mm socket and slowly pull out the assembly over
a drip pan. A piece of black foam (compensator) may come out
as part of some production models.
Damping System (Right Leg) Service – Leg Assembly
(Figures 11, 12 and 13)
The damping system contains no air and when replacing damping oil,
must be bled to remove all air.
1.
Install the rebound damper
assembly and torque the end cap
to 60–75 in.-lbs. (7.3–8.5 Nm).
2.
Hang the leg vertical at a 45º
angle as shown in Figure 11. Place
a drip pan under the leg.
3.
Fully extend the rebound damping
assembly shaft and fill with 5WT
Maxima fork oil (Answer PN 85-
3814) up to the bottom of the
inner leg threads. Cycle the
rebound damper shaft several
times, covering the open end of the leg with a rag. Allow the leg
to sit for two minutes to allow any air bubbles in the system to
rise to the top.
4.
On the compression damping assembly, remove and discard the
foam compensator if one was there during damper removal. A
replacement is found in
tune-up kit PN 85-4953.
Remove the 13 mm
adjuster needle locknut
(1). Unscrew the needle
(2) until it is loose from
the assembly, but
do not
remove.
5.
Insert the compression damp-
ing assembly with its foam
compensator (if applicable)
wrapped tightly around the
shaft into the leg. Oil will be
displaced during this step. Be
sure that the foam does not
bunch up against the leg cap
and is fully inserted into the
leg. Screw in the assembly and
torque to 60–75 in.-lbs.
(7.3–8.5 Nm) using a
20 mm socket.
6.
Install the adjuster needle and
13 mm lock nut and torque
to 10–15 in.-lbs. (1.1–1.7 Nm).
7.
Install the compression adjuster knob.
8.
Inspect the damper bleed process by compressing the rebound
shaft to the bottom out bumper. This is to ensure that the foam
compensator did not bind up internally to limit the travel. If it
does not fully compress, the system must be re-bled.
9.
Fully extend the damper shaft and install the inner leg into the
outer leg. Lubricate the bushings and inner leg as specified
under Seal System Installation.
10.
Install the damper nut using an 8 mm hex wrench and torque to
15–30 in.-lbs. (1.7–3.4 Nm).
11.
Push the rebound damper adjuster knob into the nut until it
snaps in place.
Disk Brake Adapters (Figure 14)
There are three disk brake
caliper adapters included with
the DORADO forks:
(1) International Standard
(2) Post Mount – 6" Disk
(3) Post Mount – 8" Disk
DORADO SC (Single Crown) Fork
Service (Figure 15)
Service procedures for the DORADO SC
fork are the same as for the DH model
except for the method used to remove
the left inner leg. Leg removal is
accomplished by removing the 6 mm
button head cap screw (1) on top of
the crown and pulling the inner leg
out. Re-torque the screw to 15–30 in.-
lbs. (1.7–3.4 Nm) upon assembly.
3
2
1
4
FIGURE 9
FIGURE 10
1
3
2
1
2
1
2
3
1
FIGURE 11
FIGURE 14
FIGURE 13
FIGURE 12
FIGURE 15
1 Foam Compensator
Содержание DORADO DH
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