| 1. Remove brake caliper. |
|
| 2, Loosen spindle pinch bolt |
|
3. Block up the front of the machine (just below the engine)
Remove front wheel spindle & wheel |
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| 4. Remove mudguard (or fender) |
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| 5. Remove fork brace |
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6. Remove caps on top of fork
Then loosen hex cap found under cap(1/4 turn is enough) |
|
| 7. Loosen the pinch bolts on the yolks, both upper and lower.. |
|
| 8. Slide the leg through the yolks by twisting and pulling down |
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9. Remove the hex cap from the top of the leg.
Note: these can be heavily sprung loaded, so kneed a fair amount of
pressure on the top end of the ratchet. |
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| 10, Remove top sleeve |
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| 11, then over a suitable container pour used fork oil out while removing
the washer then the main spring |
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| 12, loosen then remove the allan bolt at the bottom of the leg |
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13, making sure you catch the lower lower plunger and spring assembly
These come free when the allan bolt is totally out |
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| 14, remove the dust cap |
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| 15, remove the circlip which you'll find above the seal, some you can
remove using two screwdrivers, here circlip pliers were necessary |
|
16, pull the two parts of the leg apart, three or four pulls should
still attached to the top part of the leg from left to right,
The old seal, one washer, and two split spacers.
Using a flat head screw drive open the splits on them and slide
them off the leg, followed by the washer and seal |
|
17, replace seal and washer
Remember, when positioning seals, the writing goes up or out, so you
should be able to read them. The one I just removed were fitted incorrectly,
writing down, no wonder they leaked.
Then replace the two split spacers.
NOTE: trying to fit seals from the top of the leg damages the
seal |
|
| 18. Slide the top leg leg into the lower, then gently tap the seal
into place |
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| 19, replace circlip |
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| 20, slide lower section into the leg |
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| 21, then the spring |
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| 22, and replace the washer |
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| 23, then slide in the sleeve |
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| 24, keeping the sleeve in at the top, fit the allen bolt at the bottom
of the leg. I advise using threadlock on this bolt. |
|
25, Keeping the leg upright, fill with the correct amount of fork oil
then replace the hex cap.
Then pump with air to about 6-8 P.S.I |
|
| Note : Check your manual before you start using this page, things change
for different models, for example, my Kawasaki GPZ1000RX fork seals fit
over the forks at the top! |
Think you should be able to cope with the rest of the rebuild.
Photo's & words: Si
on the spanners, Northern Nick |
©
