Left Hand Front Fork - Disassembly

    caution
    When securing the fork in service tool T3880171, take care not to over tighten the clamp as this will cause the fork tube to distort beyond repair.
  1. Using a soft jawed vice, clamp the service tool T3880171 such that the fork can be mounted vertically.
  2. With the top cap facing upwards, very gently clamp the fork inner tube into service tool T3880171.
    3. caution
    Before loosening, cover the top cap with a suitable masking tape to protect its anodized finish from tool damage.
  3. Carefully unscrew the top cap from the fork outer tube.
    4. Fork Top Cap, cjqh_1

    1. Top cap

    2. Fork outer tube

    warning
    The fork top cap and joint rod assembly is under pressure from the fork spring. As the last few threads of the assembly are unscrewed, keep the assembly pushed firmly into the tube to prevent it being forcibly expelled as the threads release. To prevent injury, always wear eye, face and hand protection when removing the top cap and joint rod assembly.
  4. Remove the fork assembly from service tool T3880171 and transfer to a soft jawed vice.
    5. Forks in vice_1 (ckwm_1)

    1. Front fork assembly

    2. Soft jaws

  5. Hold the fork inner tube fully into the fork outer tube. Using service tool T3880367 unscrew and remove the fork top cap and joint rod assembly from the fork inner tube.
    6. Top cap/damper assembly removal, cjqi_1

    1. T3880367 - Wrench, Damper Cylinder, 33mm

    2. Top cap

    3. Joint rod

    4. Fork outer tube

  6. If removal of the top cap is required, loosen the locknut and unscrew the top cap from the joint rod. If necessary remove the O-ring joint seal from the top cap assembly.
    7. Fork top cap and joint rod assy LG1_1 (ckwl)

    1. Fork top cap

    2. Lock nut

    3. Joint rod

    note
    The spring has a smaller coil diameter at its upper end. Note the orientation of the spring before removal.
  7. Remove the spring.
    8. Fork Spring (cjrk_1.svg)

    1. Spring

    2. Fork outer tube

  8. Invert the fork and pour out the fork oil into a suitable container. Pump the fork assembly to remove all oil.
  9. With the fork still inverted, very gently clamp the fork outer tube into service tool T3880171.
  10. Ease the dust seal out of the outer tube.
    11. Fork Dust Seal, ceto_2

    1. Dust seal

    2. Inner tube

  11. Carefully ease the circlip out from the top of the outer tube.
    12. Front Fork Circlip cetn_1

    1. Circlip

  12. 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.
  13. Carefully slide the upper bush off the fork inner tube. Discard the upper bush.
    14. note
    Note the orientation of the oil seal and dust seal for installation.
  14. 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.
    15. Fork bushes and seals

    1. Upper bush

    2. Lower bush

    3. Washer

    4. Oil seal

    5. Circlip

    6. Dust seal

    7. Fork inner tube