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6.1 0 Frame and suspension
9.32 Conventional fork
-
Trekker models
1 Bottom bolt
2 Fork slider
3 Dust seal
4 Circlip
5 Oilseal
8 Spring
6 Compression limiting
9 Top bolt
cone
10 Steering stem
7 Fork tube
Pull the dust seal off the slider and drain the
then press it squarely into the slider using a
oil from the slider (see illustration).
suitable piece of tubing or a socket until the
33 Remove the circlip from inside the top of
circlip groove is visible above the seal.
the slider, then carefully prise out the oil seal,
taking care not to gouge the rim of the slider
when doing this. Discard the seal as a new
one must be fitted on reassembly.
34 Remove the compression limiting cone
from inside the bottom of the slider, noting
which way round it fits.
35 To remove the spring, unscrew the bolt in
the top of the fork tube and draw the spring
out of the tube. Hold the spring to prevent it
from tuming with the bolt.
Inspection
36 Clean all parts in a suitable solvent and
dry them with compressed air. lnspect the
fork tubes for score marks, pitting or flaking of
the chrome finish and excessive or abnormal
wear. Check the straightness of the tubes with
a straight-edge.
37 lnspect the springs for cracks, sagging
and other damage. No service data is
available for the springs, but ensure they are
both the same length.
38 Individual components are not available
for the forks, apart from the dust seal, circlip
and oil seal. If any parts are wom or damaged,
the whole fork will have to be renewed.
39 The dust seals should be a sliding fit on
the fork legs. Discard the dust seals if they are
worn or perished and fit new ones (it is good
practice to renew the dust seals when the
forks are disassembled).
Reassembly
40 Install the compression limiting cone.
41 Lubricate the new oil seal with fork oil
~p of the
ct i t wher
lace.
8
oil seal
a presslnl
42 Once the seal is installed, fit the circlip,
making sure it is correctly located in its groove.
43 Check that both plugs are in the ends of
the spring, then insert the spring into the
slider. Install the bolt into the bottom of the
slider and thread it into the plug in the base of
the spring. Hold the spring to prevent it from
tuming and tighten the bolt securely.
44 Carefully pour the correct quantity of the
specified fork oil into the slider.
45 Fit the dust seal and apply some fork oil to
the lips of the seal, then insert the top of the
spring into the bottom of the fork tube. Ensure
the fork tube fits squarely through the oil seal
and into the slider, and install the slider onto
the tube until the spring contacts the top of
the tube. Hold the slider in position, then
install the bolt in the top of the fork tube and
thread it into the plug in the top of the spring.
Tighten the bolt securely.
46 Install the steering stem (see Section 7).
Upside-down forks
(Trekker models)
Seal renewal
47 Remove the front wheel and brake caliper
(see Chapter 8). On Metal-X Furious models,
ensure the lower end of the speedometer
cable is detached from the front suspension
(see Chapter 9).
48 Unscrew the bolt from the base of the fork
slider which retains the axle/brake caliper
bracket and draw the bracket off the slider
(see illustration). Lever the dust seal off the
bottom of the fork tube and remove it.
49 Carefully prise the oil seal out of the bottom
of the fork tube, taking care not to gouge the
rim of the tube or the surface of the slider.
3 Axle bmcket
4 Forkslider
5 Dust seal
8 Compression spring
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