1. Take off wheel, brake caliper, speedo cable, and anything else attached to forks.
2. Loosen upper triple clamp bolts.
3. Put adjusters at softest settings and then loosen top cap (hard to do when fork is removed
from clamps)
4. Loosen lower triple clamp bolts and remove forks.
5. Unscrew top cap
6. Grab black cylinder thing sitting on top of spring; push down to compress spring enough that
the metal key at top of cartridge comes out.
7. Remove black cylinder thing, white preload spacers, and washer.
8. Pull out spring.
9. Dump out oil (another washer will fall out)
10. Remove bolt from bottom of fork (more oil will drip out)
11. Pry up dust seal (carefully)
12. Use small screwdriver to pry up retaining clip
13. Jerk apart inner and outer tubes (if they won't budge, apply heat to the top of the outer tube)
14. Beware of bottoming cone falling out of lower tube and onto hard concrete floor (let it slide
out gently and catch it with your hand)
15. Pump cartridge several times to get all the oil out
16. Clean everything
17. Re-assemble inner/outer tubes and cartridge
18. Carefully drive seals back in place with PVC pipe fitting (do some experimenting to see what
works) and put in retaining clips and dust seals
19. Tighten and torque bolt at bottom of outer tube (a vice makes this easier; 24n-M torque, I
think)
20. Fill'er up with 5-wt oil just below the top of the inner tube (with spring still removed)
21. Extend and retract inner/outer tube (and cartridge) to fill cartridge with oil. Do this several
times until the motion is smooth when pulling up inner tube through its entire stroke.
22. Level off oil to 145mm (inner tube fully compressed in outer tube)
23. Re-assemble spring, washers, spacers, and top cap
24. Put forks back in triple clamps
25. Torque lower triple clamp bolts (20 n-M); tighten top caps; tighten upper clamp bolts (15 n-M)
26. Put wheel, brakes, and everything else back together (always put thread lock on brake
caliper bolts)
You're Done!!
