General Rules For A Proper Overhauling - Husqvarna TC 449 2011 I.E. Workshop Manual

Workshop Manual Ed. 03-2012
FRONT SUSPENSION
TC 449 2011/2012 I.E.
TE 449 - 511 2011/2012 I.E.
TXC 449 - 511 2011/2012 I.E.
SMR 449 2011 I.E.
SMR 511 2011/2012 I.E.

General rules for a proper overhauling

• After a complete breakdown, always use new, original Marzocchi seals when
reassembling.
• To tighten two bolts or nuts that are near each other, always follow the sequence
1- 2- 1 using a torque wrench; respect the indicated tightening torques (see
Table 1 - Tightening Torques).
• Never use flammable or corrosive solvents to clean the parts, as these could
damage the seals. If necessary use specific detergents that are not corrosive,
not flammable or have a high flash point, compatible with the seals materials
and preferably biodegradable.
• Before reassembling, always lubricate the parts of the fork in contact.
• If you are planning not to use your fork for a long time, always lubricate the
forks components that are in contact with some fork's oil.
• Never pour lubricants, solvents or detergents which are not completely biode-
gradable in the environment; these must be collected and kept in the relevant
special containers, then disposed of according to the regulations in force.
• Always grease the seals lips before reassembling.
• Use only metric spanners, not imperial spanners, which may have similar sizes,
but can damage the bolts and make it impossible to unscrew them.
• Use the correct size and sort of screwdriver to unscrew slotted or crosshead
screws.
• When using a screwdriver to assemble or disassemble metal stop rings, o- rings,
sliding bushings or seal segments, avoid scratching or cutting the components
with the screwdriver tip.
• Only proceed to maintenance/ overhaul operations if you are sure you are able
to do it and you have got the right tools to do so. If this is not the case, or if
you are unsure, please contact an authorized service center, where special-
ized technicians with the right tools and original spare parts will service and
overhaul your fork, putting it back into its original working conditions.
• Only use original spare parts.
• Before servicing/ overhauling make sure you have all the spare parts you need
for the complete overhaul of both the fork legs (n° 2 oil seals, n° 2 dust seals,
n° 2 piston segments).
• Work in a clean, ordered and well- lit place; if possible, avoid servicing out-
doors.
• Before servicing the fork, we recommend washing the motorcycle thoroughly
and in particular washing the fork well.
• Carefully check there are no metal shavings or dust in the work area.
• We recommend overhauling one fork leg at a time.
• Do not modify the components of the fork.
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