14.10 ServiceManual-RocketIll

7. Removethespacer,springcapandspring.

1. Spacer

2. Springcap

3. Spring

9. Holdingboththeouterandinner tubestogether,inverttheforkandpourouttheforkoilintoasuitablecontainer.Pumpthedamperrodtoremovealloil.

10. Returntheforktothevice,clampingitasbefore.

11. Separatetheinnerandoutertubesleavingthedustandoilsealsinplaceintheoutertube.

1

ci>om

1. Innertube

2. Outertube

12.Removethedamperrodlocknuttheninsertthesquareendoftool3990090-T0301overthedamperrodandengagethesquareinthedampingcylindercupinsidethefork.Holdthehexagonalendofthetooltopreventthecylinderfromturningwhile removingthedamperboltfromthebottomofthefork.

1.Tool3880090-T0301

2.Dampingcylinder

13.Removethetool,thenthedampingcylinderfromtheinnertube.

1. Dampingcylinder

2. Innertube

14.Usingfingerpressure,removethedustsealfromtheoutertube.

1. Dustseal

2. Outertube

_- ServiceManual-RocketIll

14.11

15.Removethecirclipfromabovetheseal.

1.Circlip

16.Notetheorientationoftheseallipthen,usingasoft-faceddrift,removethesealandcollectthewasherfrombelowit.

1.Sealremoval

Inspection

1. Inspecttheinnertubeforstonechips,scoring,scratches,excessivewearandanyotherdamage.Renewtheinnertubeifnecessary.

2. Inspectthespringfordamage,cracksanddeformation.Renewthespringifnecessary.

3. Inspectallbushesandsealsfordamage.Renewanydamageditemsifnecessary.

Assembly

Note:

• Ifthedamperhasnotbeenremoved,omitoperations6 and7.

1. Applyasmearofforkoiltothebushes andseals.

2. Fitthewashertothesealrecessintheoutertube.

1.Outertube

2.Washer

14.12 ServiceManual-RocketIll

3.Positionthesealasnotedpriortoremoval,thenpositionittotheoutertubeanddriftintoplaceusingtool3880080-T0301.Retainthesealwithanewcirclip.

1.Seal

2.Tool3880080-T0301

4. Refitthedustseal,usingfingerpressureonly.

""'"

1. Dustseal

2. Outertube

5.Carefullyfittheoutertubetotheinnerensuringthattheoilanddustseallipsdonotbecomedamaged.

1. Innertube

2. Outertube

6. Fitthedampertotheinnertubeandengagetool3880090-T0301tothedampercup(asforremoval).

7. Cleanthethreadsofthedampingcylinderboltandfitanewsealingwasher.Applyadropofthree-bond1342tothethreadstheninstallthebolt.Preventthecylinderfromturningbyholdingthehexagonalendoftool3880090-T0301whiletighteningthedampingcylinderboltto45Nm.

1.Tool3880090-T0301

2. Cylinder

• ServiceManual-RocketIll

14.13

B. Refitthedampingrodlocknutleaving15.5mmofthreadandrodexposedabovethenut.

9. Filltheforkwithoilasdescribedonpage14.7.

10. Positiontheassemblyasforcompressionoftheforkspring.

11. Insertthe forkspringandspringcaptotheoutertube.

12. Attachtool38BOOB5-T0301tothethreadsofthedamperrodandpullthedamperupwards.

'"'"

1.Tool3BBOOB5-T0301

13. Refitthespringspacer.

14. RefittoolT38B0067tothespringspacer,compresstheforkspringandrefitthespringholder.

1. ToolT3BB0067

2. Springholder

15. Refitthetopcaptothedamperrod

16. Holdthetopcapwhiletighteningthedamperrodlocknutto16Nm.

15. Recompressthespringtoremovethespringholder.

1B.Lubricatethe0-ringonthetopcapwithasmearofforkoilthenscrewthetopcapfullyintotheinnertube.

19. Tightenthetopcapto30Nm.Note:

    • Itismucheasiertotightenthetopcapwhentheforkissecurelyclampedinthebottomyoke.

20. Installthefork(s)asdescribedonpage14.5.