Cleaning The Fork Legs; Disassembly; Assembly - Husqvarna TC 250 2010 Workshop Manual

Cleaning the fork legs

This can be done with the fork installed.
The dust seals of Marzocchi forks are grease lubricated so the inner tubes will
slide more easily, especially after long period of inactivity.
This grease may melt in service and run down the inner tubes, so the fork will
look like it is leaking oil.
Inspect the suspension to establish whether an oil leak exists. Clean the outer
surfaces of the fork, especially inner tubes and dust seals, thoroughly after
each use.
WARNING
Do not ride a motorcycle with a leaking fork. Eliminate any oil leaks before
using the motorcycle.

Disassembly

Thoroughly clean the inner tube (44) before disassembly.
Prise the dust seal (16) off the outer tube (11) with a small screwdriver, taking
care not to scratch or damage inner and outer tube.
Slide the dust seal over the inner tube and blow the inner side of the dust seal
and its seat in the outer tube with compressed air.
Lubricate the dust seal and the visible surface of the sealing ring with silicone-
based grease.
WARNING
Any bugs sticking to the fork legs must be cleaned off promptly, or they
may cause severe damage to the suspension.
WARNING
Never use metal tools to dislodge dirt.
Pump the fork legs through a short stroke and remove any dirt from the inner
tubes (44).
Wipe off any oil/grease and dirt with a soft cloth.
Lubricate the dust seal and the visible surface of the sealing ring with silicone-
based grease.

Assembly

Slide the dust seal (16) over the outer tube (11) and push it into place with your
hands.
Part. N. 8000 H1489 (10-2009)
FRONT SUSPENSION
I.33