- Remove the fork assembly (see Front fork - removal).
- Drain the fork oil (see Fork oil change - oil draining).
Fork top cap removal
Note: It is only necessary to remove the fork top caps if they are to be replaced.
1. If removal of the fork top cap is required, loosen the lock nut and unscrew the top cap from the joint rod. If necessary remove the O-ring joint seal from the top cap assembly.
1. Fork top cap; 2. Lock nut
Note:
- The left hand and right hand fork leg assemblies differ internally, with the left fork leg containing an adjustable preload assembly and the right fork leg containing an adjustable damping assembly.
- When removing the left hand (preload adjuster) top cap, note the position of the preload adjuster rod located inside the joint rod. Ensure the adjuster rod remains correctly located for installation.
- When removing the right hand (damping adjuster) top cap, note the position of the inner and outer damping adjuster rods located inside the joint rod. Ensure both adjuster rods remain correctly located for installation.
1. Preload assembly joint rod; 2. Preload adjuster rod; 3. Damping assembly joint rod; 4. Outer damping adjuster rod; 5. Inner damping adjuster rod
Fork inner and outer tube disasembly
Caution! When securing the fork in T3880171 - Fork Holding Tool, take great care not to over tighten the clamp as this will cause the fork tube to distort beyond repair.
1. Ease the dust seal out of the outer tube.
1. Dust seal; 2. Inner tube
2. Carefully ease the circlip out from the top of the outer tube.
1. Circlip
3. Compress the fork then pull the inner tube sharply out of the outer tube. Repeat this procedure until the upper bush and seal are forced out of position and the inner and outer tube can be separated.
4. Carefully slide the upper bush off the fork inner tube. Discard the upper bush.
Note: Note the orientation of the oil seal and dust seal for installation.
5. Slide the lower bush, washer, oil seal, circlip and dust seal off the fork inner tube. Discard the lower bush, oil seal, circlip and dust seal.
1. Upper bush; 2. Lower bush; 3. Washer; 4. Oil seal; 5. Circlip; 6. Dust seal; 7. Fork inner tube