Moto GP Racer
Join Date: Mar 2007
Thanked 197 Times in 143 Posts
Feedback Score: 9 reviews
OK, back to it. After you remove the fork bolt, you can take off the spring holder. You can now pull out the two white plastic pieces, the rubbber gromet, and the spring itself. Next, dump out the fork oil. You can pump the fork tube up and down a bunch of times to help get the oil out. You will never get it all out, so it will continue to be a big mess throughout the process. According to the manual, the next step is to remove the damping adjuster from the bottom of the fork. Having done it once, I don't think it is necessary, although it's pretty easy.
The next step has a lot of potential for screw ups, so be careful. You have to remove the bolt at the bottom of the fork. There are several issues. First, the bolt is recessed way up into the fork, so your typical hex bit won't reach it. Also, the bolt itself is super shallow, so it is easy to strip out. I bought a set of long reach hex sockets for this job, but they were ball-end (all they had) so they didn't work on the shallow bolt head. Pisssed me right off. Two other potential problems. That bolt is usually on very tight (25 ft-lb). That doesn't seem like alot, but there is really no way to hold it still while you apply pressure unless you have a vise, which I don't. I ended up using the long end of an 8mm hex key and using the axle to increase my moment arm. Pictured here. Once it breaks loose you have to hold the damper rod from the top while you unscew the bolt. Also, you have to remove one of the axle pinch bolts to get the bolt all the way out. Note: I figured out a better way to get the bolt loose / tight when I put it back together. I'll show you later.