14.6 ServiceManual-RocketIll

Oilrefilling

TheoillevelspecifiedforRocketIllforksis89mmfromtheuppersurfaceoftheforkoutertube,with theforkfullycompressed.

Forkoillevel(forkfullycompressed)

1. FilltheforkwithSAE5w(orKayabaKHL15-10forkoiluntiltheoillevel isslightlyabovetherecommendedlevel.Alternativelyadd667ccofoiliffillingacompletelyemptyfork.

2. Pumptheforkassemblyanddamperseveraltimes toexpelany trappedairthenfullycompresstheforkandsupportiiinanuprightposition.Leavetheforkforafewminutestoallowtheoilleveltostabilise.

3. Setthescaleontool3880160-T0301tothespecifiedlevel(dimensionAbelow).

cl>yg

1.Tool3880160-T0301

2. Adjusterplate

3. Scalearea

4. Hole(zeroposition)

Note:

• Zerolevelonthetoolissetatthesmallexitholeinthesideofthescaletube,NOT ATTHEENDTIP.Donotattempttoblockthisside-hole,asthiswillcausethefinalfluidleveltobeincorrect.

4. Insertthescaleendofthetoolintotheforkinnertube.

5. Holdthetooladjusterplatelevelwiththeuppersurfaceoftheforkoutertubeanddrawfluidintothesyringeuntilfluidflow ceases(emptythesyringeifthebodybecomesfullbeforefluidflowstops).

6. Thefluidlevelintheforkisnowsettotheheightsetonthe toolscale.Checkthetoolscalesettingandrepeatthe processifincorrectlyset.

Incorrectoillevels,particularlyoverfilling,canresultindamagetotheforkseals.Damagedforksealsareadangerousridingconditionthatcanleadtolossofmotorcyclecontrolandanaccident.

4. Positionthefork assemblyasforcompressionoftheforkspringduringstripdown.

5. Inserttheforkspringandspringcaptotheoutertube.

6. Attachtool3880085-T0301tothethreadsofthedamperrodandpullthedamperupwards.

1.Tool3880085-T0301

4. Refitthespringspacer.

ServiceManual-RocketIll

14.7

13. Relitthetopcaptothedamperrod.

14. Holdthetopcapwhiletighteningthedamperrodlocknutto16Nm.

4. RefittoolT3880067aspreviouslydescribed,compresstheforkspringandrefitthespringholder.

1.ToolT3880067

2.Springholder

12.Refitthedampingrodlocknutleaving15.5mmofthreadandrodexposedabovethenut.

15. Recompressthespringtoremovethespringholder.

16. Lubricatethe0-ringonthetopcapwithasmearofforkoilthenscrewthetopcapfullyintotheinnertube.

17. Tightenthetopcapto30Nm.Note:

    • Itismucheasiertotightenthetopcap

whentheforkissecurelyclampedinthe

bottomyoke.

14.8 ServiceManual-RocketIll

FrontFork

Disassembly

1. Topcap

2. 0-ring

3. Spacer

4. Springseat

5. Spring

6. Damperrod/cylinder

7. Innertube

8. Dustseal

Forkcomponents

9. Circlip

10. Oilseal

11. Washer

12. Bush

13. Outertube

14. Sealingwasher

15. Damperrodbolt

• ServiceManual -RocketIll ^14.9

1. Removetheforksasdescribedonpage14.9.

2. Securetheforkinasoftjawedvice,gentlyclampingitonthecalipermounting.

""''

1.Fork

2. Calipermounting

Note:

• Theforksealscanberenewedwithoutremovalofthedampingcylinder.Unlessremovalofthedampingcylinderisnecessary,omititems3,11and12.

3. Unscrewthetopcapfromtheoutertube.

Note:

• Thetopcapisnotunderspringtension.

Removetheforkfromtheviceandhaveanassistantstandituprightonthefloor.

FittoolT3880067overthetopcap.Positionthetwoadjustablearmstotheholesinthespringspacer.Screwinthearmsuntiltheypositivelyengageinthespringspacer holes.

3. UsingtoolT3880067,manuallycompresstheforkspringandinsertthespringholderbelowthedamperlocknut.

"""

1.Damperlocknut

2.ToolT3880067

3.Springholder

7. Slackenthelocknut,unscrewandremovethetopcap.Recompresstheforkspringtoremovetheholder.