Buell 2009 XB Series Service Manual page 156

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sm00569
Figure 2-98. Fork Seal Driver
sm03830
Figure 2-99. Damper Rod Retrieval Tool
11. Once again install the bottom of the slider tube (22) in the
vise using soft jaws.
NOTES
The recommended fork oil is hydraulic fork oil Type "E"
(Part No. HD-99884-80.
The fork spring should not be installed for this part of the
procedure.
12. With the fork fully collapsed, fill the fork with oil until it
reaches the threads on the outer tube.
2-78 2009 XB Service: Chassis
13. See Figure 2-99. Thread damper rod retrieval tool found
in the Race Tech Inc. FORK BLEED TOOL SET (Part
No. TBFT 02S) onto end of damper rod assembly (6). See
Figure 2-96.
NOTE
While pumping the outer tube up and down be sure not to
exceed the travel of the fork assembly.
14. Pump the outer tube up and down approximately 6 inches
10 times.
15. See Figure 2-96. Collapse the fork again and once bub-
bling has stopped, pump the damping rod up and down
its full stroke until consistent resistance is felt for the entire
stroke.
16. See Figure 2-100.With fork completely collapsed, adjust
fork oil level with FRONT FORK OIL LEVEL GAUGE (Part
No. B-59000A) to the specified level below the top of the
outer tube. Refer to Table
NOTE
When installing the fork spring verify that the tighter wound
portion of the spring is installed down.
17. See Figure 2-96. Install the fork spring (12), fork spring
joint (11) and fork spring collar (10) over the damper rod
retrieval tool.
NOTE
Be sure to never over compress the fork assembly.
18. Remove the fork slider from the vise and install the fork
assembly in the front fork compressor.
19. See Figure 2-93. Compress the fork spring until you have
access to the damper rod assembly with jamnut.
20. Remove the damper rod retrieval tool while holding onto
the damper rod with your fingers.
NOTE
Make sure you place the damper rod jamnut at the bottom of
the threads.
21. See Figure 2-96. If the fork push rod (4) has been removed
from the fork cap assembly (1) install at this time.
22. When installing the fork push rod with fork cap, insert it
into the damper rod and allow it to float down until it stops.
23. Thread the fork cap onto the damper rod until it stops. Do
not tighten.
NOTE
Before tightening the damper rod jamnut, back the rebound
adjuster out 1/4 turn to prevent damage to the tapered end of
the fork push rod.
24. Thread the damper rod jamnut until bottoms lightly on the
rebound adjuster assembly in the fork cap.
25. Tighten the damper rod jamnut (2) to 22-30 ft-lbs (30-41
Nm).
26. Remove the fork assembly from the front fork compressor
and install in the fork holding tool and install in vise.
27. See Figure 2-96. Thread fork cap (3) into fork tube (18)
and tighten to 22-30 ft-lbs (30-41 Nm).
2-26.