REMOVING

Remove front wheel, mudguard, and temporarily install fork in a pinch bolt to loosen the top cap. Just loose it.




Then remove the fork cap.




Push the pipe down and remove spring collar.




Remove joint spring washer.




Remove fork spring.




Drain the oil by pumping the pipe several times.




To separate pipe from base, loosen this hex bolt this way using adjustable spanner, it will be easier to loose. And use any pipe or just any ring spanner to apply the torque easily.






When you have loosen the bolt, the piston inside will rotate freely. Then insert piston removal tool to hold the piston inside. Remove the bolt and pull the pipe out.







Remove the piston out and remove the rebound spring.




Remove oil seal lock.




And remove oil-seal this way using cloth, that will prevent the base from being damage. Also don't damage the oil-seal seat while removing oil seal.




INSPECTION

Inspect piston, pipes, base for any score marks, scratches or abnormal wear. Check piston ring for any fatigue or damage. Replace any components that are worn or damage.

Place the pipe in a V blocks, or flat surface (I prefer glass) and check if it is bent or straight. If found bent then get it straight on a lathe or simply buy a new one.
It should not be more than 0.20 MM run out.

Before assembly, wash all parts with a high flash/non-flammable solvent (kerosene) and wipe them dry.


INSTALLATION

Apply new fork oil around oil seal lips and install it in a base with its marking facing up or two rings facing downwards. Use old oil seal to drive it inside or simply use oil seal driver tool if you have after installing pipe. Then install oil lock.






Insert piston inside fork pipe and insert oil lock piece. And drive it inside the base. Before inserting apply fork oil to the oil seal to prevent dry sliding.




Replace both O-ring and washer before installation. You can also apply gasket sealant to the copper washer to ensure better sealing.



Then insert piston remover tool and tighten the piston socket bolt.
TORQUE: 20 N�m (2.0 kgf�m, 15 lbf�ft)

Install dust seal. When you will be sliding dust seal from up to down it will carry dust with it. Then pull it up and clean the dust. Repeat this several times and then install it. This will ensure you there is no dust below the dust seal cap.

After fitting, push the pipe all the way down and pour exactly 160 ml of new fork fluid.
(Check your owners manual before pouring, it is different for different manufacturers)


Pull the fork pipe up and insert fork spring with its tapered (narrow coil pitch) facing downward.




Then pump the fork pipe 10~15 times up and down to remove trapped air from the lower portion of the fork pipe.




Install washer, collar. Apply fork oil to the new cap o-ring and install the fork cap on to the fork pipe. Press and rotate until it catches the thread.




Then temporarily install fork on your bike pinch bolt and tighten it.
TORQUE: 22 N�m (2.2 kgf�m, 16 lbf�ft)


Rotate your fork opposite so that fluid touches the collar. That will prevent your collar from being rusted.




Then install it on your bike. And drive on to test it