Parts needed
Y8501451, 38mm seal kit
Y5249, SAE 7.5w oil
Tools Required
YR5214/C, 38mm seal press
General Tools
1.5, 2mm allen wrench
17, 24mm socket
Torque wrench
Service Instructions
Disassembly
1/ Remove all adjuster knobs, be careful when removing the pre-load knob not to loose spring (95) and ball bearing (96) that index’s the adjuster.
2/ Undo both top plugs using a 24mm socket.
3/ Remove spring guide (53) and main spring (51).
4/ Pour oil out of the top of the fork. Make sure you use a suitable container and recycle responsibly.
5/ Undo both foot nuts, RH (37) using a 5mm hex key, LH (88) using a 17mm socket.
6/ Remove RC3 cartridge unit (80).
7/ Separate the stanchions (21) from the lower legs (3) by simply pulling them apart.
8/ Prise the dust seal up (12) using a flat bladed screw driver.
9 /Remove foam ring (19).
10/ Remove oil seal retaining clip (13).
11/ Remove oil seal (14) using tool Y536064GG/C and a flat bladed screw driver.
12/ Inspect and clean all parts.
Assembly
13/ Install new oil seal (14) using press tool YR5214/C
14/ Install oil seal retaining clip (13).
15/ Install dust seal (12) on to the stanchion (21).
16/ Install foam ring (19) on to stanchion (21). For best performance pre-soak rings in SAE 7.5w fork oil.
17/ Insert stanchions (21) in to the lower legs (3), making sure you do not snag the oil seal.
18/ Using your thumbs seat the dust seals in to the lower leg.
19/ Re-fit RC3 cartridge unit (80).
20/ Re-fit both foot nuts and torque to 10NM.
21/ Re-fill with SAE 7.5w synthetic motorcycle fork oil. For oil volumes please refer to the oil volume table is these differ on model years/ Damper design.
22/ Cycle RC3 damper (80) several times to ensure the cartridge fills completely.
23/ Re-fit the main spring (51) and spring guide (53).
24/ Re-fit both top plugs and torque to 10NM.
25/ Re fit adjusters.
