This is Part 2 of our Fork Seal and Oil Replacement video.
Place refer to Part 1 for disassembly.
Now is a great time to refer to your owners manual for parts inspection.
This is the order it's going to go back on, you have your dust seal, your retaining clip,
your oil seal, your washer, your outer bushing and your inner bushing.
Go ahead and stand it up and put it in a vise.
We're using soft jaws on this so be really careful not to mar your fork leg.
next we're going to put the Motion Pro Seal Bullet on and this is going to protect our
dust seal and oil seal from the grooves that hold the inner fork bushing on.
Go ahead and grease it up.
We're also going to take out dust seal and we're going to grease it so it slide down.
Next is our retaining clip, and then our oil seal.
A little extra grease in there never hurt anything, this of course is our seal grease.
Slide that over and then when you get to the bottom be careful and make sure you get it
over that last groove without tearing any of the seal.
Now we're going to go ahead and remove the seal bullet and then we're going to slide
the washer on, the outer bushing, the inner bushing and this is the one that sits in the
groove so spread it a little bit and slide it down until it clips into place.
Now we are going to take the outer fork tube, slide it down.
We're going to grab out Tusk Seal Driver and go ahead and drive the bushing and the washer.
Just a couple light taps, you can actually hear the sound it makes when it bottoms out.
We're going to go ahead and remove those and then we're going to drive the seal, the actual
oil seal and once again go ahead and drive that in and you'll be able to hear the different
sound it makes.
You'll know when its all the way seated.
Next we want to install the retaining clip, go ahead and slide that into place.
And just to make sure that it clicks in you can go ahead and use your seal driver again
and you can actually hear it snap.
Sometimes a visual inspection to make sure its seated all the way.
And then slide your dust seal on just using your fingers to push that on.
Now it's time to reassemble, we're going to go ahead and put the push rod into the damping
rod and we're going to fill it with oil.
You're going to want to fill it nearly to the top and then what we're going to do now
is we are going to go ahead and lift the outer tube about 6-8 inches maybe a couple times.
Now what you want to do is grab the inner damping rod and run that through its stroke
and do it slowly.
On some of the older ones oil will actually squirt right out of the end of the rod so
be careful.
And what we're doing here is we are filling the cartridge full of oil and getting the
air out of it.
It might be necessary to add some more oil just so, you can feel it as you pull that
rod through its stroke if there's any air left.
You want a nice smooth action.
Now its time to add oil using our Tusk Fork Oil Level Tool and when we measure the oil
we want to make sure and have everything in the fork except the spring.
The damping rod completely compressed, the fork outer tube completely compressed and
we're going to measure from the outer fork tube down to the oil.
Go ahead and refer to your service manual and get your fork oil level height and set
the laser etched marks on the fork oil level tool and then basically what you're going
to do here is you're going to pull oil out of the fork and so it's going to need to be
a little bit overfilled to get the level correct.
Once it starts to suck air then you know that you're at the correct height.
Alright the next thing that we're going to do is pull the damping rod up until it's fully
extended.
We're going to put the spring on.
You kind of half to hold it up as you're pushing the spring on, kind of hold it with your other
hand.Then you have your spring centering washer that goes on next and then your fork cap and
at this point you want to make sure that your locknut is threaded all the way down to give
your fork cap as much thread as possible.
And then you slide the wrench in, it holds the fork spring down.
Then you're going to back that lock nut up against your fork cap.
Go ahead and make sure that's fairly tight.
Alright our next step, we're going to go ahead and pull up our outer fork tube and thread
the fork cap back into it.
The next thing we want to do here is set our rebound back the where it was and you're ready
to mount it on the bike and lets go ride!