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Damper Rod Disassembly
IMPORTANT NOTES
See
Figure 2-67.
Disassembly of damper rod is not required
unless damper locknut (10) has been moved. If damper rod
needs servicing refer to the Firebolt Parts Catalog (Part No.
99574-03Y) for kit information.
If damper locknut has been moved, proceed with the follow-
ing disassembly and assembly procedures for setting the cor-
rect range of motion.
1.
See
Figure 2-59.
Lightly turn the rebound adjuster screw
(1) counter clockwise till it stops.
2.
See
Figure 2-67.
Holding the damper locknut (10),
unscrew the rebound adjuster assembly (9) and remove
from damper rod assembly (11).
3.
Remove damper locknut (10) from damper rod assembly
(11).
CLEANING AND INSPECTION
1.
Thoroughly clean and inspect all parts. Replace any
parts that are bent, broken or damaged.
2.
See
Figure 2-67.
Check the slide pipe (27) and outer
tube (18) for score marks, scratches and excessive or
abnormal wear. Replace if worn or damaged.
3.
Check the slide bushing (21) and the guide bushing (22)
for excessive wear or scratches. Replace if damaged or
worn.
4.
Replace the stopper ring (19) if distorted.
5.
Measure spring (16) free length. Replace springs shorter
than service wear limit of 9.13 in. (232 mm).
6.
See
Figure 2-62.
Measure slide pipe runout. Replace
pipe if runout exceeds the service wear limit of 0.008 in.
(0.2 mm).
b0776x2x
Figure 2-62. Pipe Runout
ASSEMBLY
Damper Rod Assembly
Skip to fork assembly if damper rod assembly was not disas-
sembled.
1.
See
Figure 2-67.
Fully thread the damper rod locknut
(10) on to damper rod (11) clockwise till it lightly bottoms.
NOTE
Set both forks to the exact same suspension settings.
2.
Adjust rebound assembly for proper range of motion.
Note
a.
Lightly turn the rebound adjuster screw (9) counter
clockwise till it stops.
b.
Turn the rebound adjuster screw three full turns
clockwise.
3.
Fully thread rebound adjuster assembly (9) onto the
damper rod assembly (11) until it lightly bottoms. Do not
tighten.
4.
Thread the damper locknut (10) until bottoms lightly on
the rebound adjuster assembly. Do not tighten
5.
Turning the rebound adjuster screw (9) counter clock-
wise three full turns or until stops.
6.
Tighten the damper locknut (10) to 22-30 ft-lbs (30-
40 Nm).
7.
Repeat for other fork assembly.
8479
1.
Fork cap assembly
2.
Rebound assembly
Figure 2-63. Rebound Assembly and Fork Cap Assembly
Fork Assembly
1.
See
Figure 2-67.
Wrap the end of the slide pipe (27) and
the slide bushing channel with tape to avoid damaging
the oil seal lip when installing.
2.
Install a new dust seal (26) and stopper ring (19) onto
the slide pipe (27).
3.
Coat the sealing lips of the new oil seal (24) with fork oil
or sealing grease and install onto the slide pipe with its
marked side facing the dust seal (26).
4.
Remove the tape from the slide pipe end.
5.
Install the seal spacer (23), the guide bushing (22) and
the slide bushing (21) onto the slide pipe (27).
6.
Coat the slide bushing (21) and the guide bushing (22)
with fork oil.
CAUTION
The outer tube can move freely up and down on the slide
pipe. Always hold both the slide pipe and outer tube to
prevent damage to bushings and seals.
7.
See
Figure 2-67.
Drive the guide bushing (22) with the
seal spacer (23) and oil seal (24) into position in the
outer tube using a FORK SEAL DRIVER (Part No. B-
43721). See
Figure 2-64.
8.
Install the oil seal stopper ring (25) and a new dust seal
(26).
2003 Buell XB9R: Chassis
2
1
2-41
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