Fork Oil Replacement - Cobra 2007 CX65 Owner's Manual

Fork Oil Replacement

Requirements
• 19mm and 27mm combination wrench
• 6mm and 10mm hex key (Allen)
• Flexible retrieving tool
• 10w fork oil (approximately 210cc per fork leg)
Disassembly
1. Remove the front wheel and front brake caliper.
2. Remove the fork legs from the triple clamps.
3. Perform the following on each fork leg:
a. Remove the fork cap using a 27mm wrench.
b. Lower the fork tube to expose the fork spring.
c. Pull the fork spring down from the fork cap to
expose the damper rod lock nut. Secure this nut
using a 19mm wrench.
d. With a 19mm wrench on the damper rod nut, use
a 27mm wrench to free the fork cap from the
damper rod.
e. Remove the 19mm wrench and allow the damper
rod to fall into the damper tube.
f. Remove the fork spring and spacer.
g. Invert the fork while pumping the damper rod
assembly several times to help the oil drain.
Assembly
1. Completely collapse the outer fork tube onto the stanchion tube. Add enough
oil to the fork to fill the cartridge tube. Pump the damper rod up and down
slowly to help the assembly fill with oil.
2. Once the cartridge assembly is bled, continue to fill the fork with oil until it is
120mm +/- 2.5mm from the top of the fork.
3. Install the fork spring.
4. Use a flexible retrieving tool to pull the damper rod up through the fork spring
(Figure 6.). Pull the fork spring down from the damper rod to expose the
damper rod lock nut. Secure this nut using a 19mm wrench.
5. Install the spacer and fork cap to the damper rod. Ensure that the fork cap is
completely threaded onto the damper rod before it makes contact with the
lock nut. Torque the damper rod lock nut to 15N-m (11ft-lb).
6. Install the fork cap to the fork tube. Torque the fork cap to 20Nm (15ft-lb).
7. Pump the fork leg several times to verify that it operates smoothly.
8. Install each leg back into the triple clamp. Torque each pinch bolt to 11N-m (8
ft-lb) making sure both legs are set to the same height in the clamps.
9. Install the front wheel, and torque the axle to 13.5N-m (10 ft-lb).
10. Drop the bike onto the ground, engage the front brake, and push up and
down on the handlebars several time to ensure that the front forks and the
front wheel are properly aligned with each other.
11. Tighten the axle pinch bolts to 10N-m (7.4 ft-lb).
Figure 6.
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