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Reassembly of the front fork
Lock the fork tube - calliper unit.
Protect the end of the unit with tape.
Important
Before installation, smear the sliding edges of sealing ring (21) with fork oil or oil seal grease.
Install the sealing ring (21) with the marked surface facing the dust seal (15).
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Install the following components in the fork tube - calliper unit (6):
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dust seal (15);
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circlip (17);
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sealing ring (21);
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collar (27);
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bottom bush (26);
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bottom bush (11).
Note
Before assembling the fork tube - calliper unit with the outer tube, lubricate the bush sliding surfaces with fork oil.
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Push the bottom bush (26) and the cap (27) into the external sleeve (18) using the sealing ring tool (F,*part no.*88713.3204).
Drive the oil sealing ring (21) into the outer tube using the same tool.
Fit the circlip (17) and the dust seal (15).
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Important
The outer tube must freely slide on the fork tube - calliper unit. Only support the sliders and the outer sleeve with your hands to avoid damaging the sealing rings and the bottom bushes.
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Insert the cartridge assembly (8) in the fork tube - calliper unit (6), screwing the tool 88713.3203 onto the cartridge.
Install the gasket (4) and the compression set screw (3) and tighten to the torque (Sect.*3 - 3, Frame torque settings).
Insert half of the prescribed quantity of oil in each fork leg (Sect.*3 - 2, Fuel, lubricants and other fluids).
Pump with tool 88713.3203 to force the oil to fill internal volume completely.
Slide both the damper and outer tube fully down the inner tube.
Pour the remaining oil into the fork leg and measure the oil level.
Important
Keep the fork leg vertical when measuring the oil level. Make sure the oil level is the same in both fork legs.
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Recommended oil:
SHELL ADVANCE FORK 7.5 or DONAX TA
Standard capacity:
0.480*dm3 for each fork leg.
Standard oil level:
104*mm.
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The quantity of oil affects fork response during the final part of the compression stroke.
High oil level increases compression loading, low oil level will decrease it.
Clean off any oil from the spring (9) and the counter nut (13) before refitting.
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Install the preload tube (12).
Insert the spring (9), bush (15) and counter nut (13), with the conical side facing counter nut (26).
Screw the counter nut (13) onto the damper (8) with a wrench.
Using the same wrench, restrain the counter nut and screw the top cap (7) complete with the O-ring onto the damper (8).
Tighten the upper plug (7) to the specified torque (Sect.*3 - 3, Frame torque settings).
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