A Fork Maintenance Guide
We are going to have to break them down so before you remove them take out the top plug and the spring. This is easier if you used a 2 legged wheel puller over the top triple clamp to hold down the spring will you fish out the lock ring.
Tip Here: Bend the last 1/8” of the ring up and in to make it easier to remove the next time.
Tip 2: Have the plug drilled and tapped for a taper pipe plug to make later oil changes easier.
Step one: with the bike on the centre stand and the front end blocked in the air. Remove the wheel, fender and the brake caliper from the forks, don’t break the Hyd line.
Optional: remove the fairing.
Loosen all the triple clamp bolts and slip the tubes down and out
Tip 3: If the tubes are tight a screwdriver tapped into the clamping point split will open the clamps and allow the tube to slip out easier.
Pour out the oil
Invert the fork tubes and remove the Allen hex bolt in the bottom center
Tip 4: be very careful not to push on the wrench just turn it and remove the screw completely. If you screw up and the inner part turns, then you need a long something to jam down inside to hold it while you turn out the screw.
Pry out the dust cap
Remove the snap ring under the dust cap.
Slam the slider to full extension repeatedly till the thin come apart. You are driving out the top bearing and the seal.
Invert the tube and dump out the plunger rod.
Invert the slider and dump out the aluminum plunger rod seat.
Ok the forks are all apart. Depending on what you wanted in here for in the first place. Now do it.
Install Emulators (follow those instructions
Change bearing or seals now.
Before re assembling inspect the tubes very carefully for any knocks and stone them smooth.
Tip5: Take a ladies stocking and wipe it all over the tubes to feel for any catches. Stone they smooth.
NOW’s a good time to add a drain screw in the slider. Drill and tap a small hole in the back side of the slider about ˝” above the beginning of the round part and fit a plug with a rubber or nylon washer.
Re assembly:
Drop the plunge rod into the tube and drop the plunger rod seat into the slider.
Slip the tube into the slider and screw in the Allen hex bolt tighten the bolt, you may need that long thing again here.
Drop on the top bearing and with a seal driver seat it home.
Tip 6: A seal driver is just a tubular thing that fits over the tube and pushes the bearing home. A Piece of hard wood shaped to fit into the space will work.
Put on the new seal with the lip facing down
Drive it home
Add the washer and the snap ring and the dust cap. .
After installation be sure to “Rock’ the forks before you tighten all the bolts.
Drop in the spring and add 270 cc oil to each leg and install the plug and snap ring and your done.
Leave a Comment