Right 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

  4. Loosen the lock nut, unscrew and remove the top cap. If necessary, remove the O-ring seal from the top cap assembly.
  5. Invert the fork and pour out the fork oil into a suitable container. Pump the fork assembly to remove all oil.
  6. Return the fork to the clamping tool.
    7. warning
    While compressing the fork spring always wear protective equipment for the face and eyes and never stand directly above or look directly down on the fork. If the spring compressor should dislodge or detach, the resulting release of spring tension could cause parts to fly off resulting in injury to the user.
  7. Fit service tool T3880067 over the spring spacer. Position the two adjustable arms to the spring spacer. Screw in the arms until they positively engage in the spring spacer holes.
  8. Using service tool T3880067, manually compress the fork spring and remove the split collar from below the damper lock nut.
    9. Compress the fork spring, cgyh_1

    1. Damper lock nut

    2. T3880067 - Fork Spring Compressor

    3. Split collar

  9. Remove service tool T3880067 from the spring spacer.
    10. note
    The spring has a smaller coil diameter at its upper end. Note the orientation of the spring before removal.
  10. Remove the spring spacer, washer and spring.
    11. Fork spring, washer and spring spacer, cdno_3

    1. Spring spacer

    2. Washer

    3. Spring

    4. Damper rod

  11. Invert the fork and very gently clamp the fork outer tube into service tool T3880171.
  12. Ease the dust seal out of the outer tube.
    13. Fork Dust Seal, ceto_2

    1. Dust seal

    2. Inner tube

  13. Carefully ease the circlip out from the top of the outer tube.
    14. Front Fork Circlip cetn_1

    1. Circlip

  14. 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.
  15. Carefully slide the upper bush off the fork inner tube. Discard the upper bush.
    16. note
    Note the orientation of the oil seal and dust seal for installation.
  16. 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.
    17. Fork bushes and seals

    1. Upper bush

    2. Lower bush

    3. Washer

    4. Oil seal

    5. Circlip

    6. Dust seal

    7. Fork inner tube

  17. If removal of the damping cylinder is required, unscrew the damping cylinder bolt from the bottom of the fork. Discard the sealing washer.
  18. Slide the damping cylinder out of the fork inner tube. Collect the centering collar from the lower end of the damping cylinder.
    19. Damping cylinder (ccuy.svg)

    1. Damping cylinder