Hi, I'm Eric from Rocky Mountain ATV/MC.com and today I'm going to show you how to change
the oil and fork seals on a cartridge type fork.
To start you will need some common tools and some specialty tools like the Motion Pro Seal
Bullet, the Tusk Fork Oil Level Tool, Race Tech Seal Grease, Tusk Seal Drivers and clean
rags but most importantly you will need a service manual, which will contain the proper
procedures for your machine.
It will also list the appropriate oil level and type.
Rocky Mountain sells a wide variety of fork oils.
First off we're going to back out the rebound adjustment screw all the way.
This will make certain that the cap threads completely back onto the damper rod during
reassembly.
Now it's time to thread the cap off the outer tube.
We're going to go ahead and slide the outer tube down, it's going to expose a spring and
there's also a lock nut right there.
You're going to pull down the spring and insert your wrench on the lock nut.
This will also hold the spring down.
Go ahead and back the cap off the damper rod and the lock nut.
Go ahead and remove the spring, place it on your clean rag.
There's also the push rod that's inside the damper rod, pull that out and sit it on your
rag.
Next we're going to go ahead and dump the oil out.
Pump it a couple times, make sure all the oil is out.
This makes a pretty good mess so it's always a good idea to have a good sized drain pan
to do this in.
You want to go ahead and pump it until you can feel that all the oil is out of that damper
rod.
Now we are going to go ahead and remove the dust seal, flat bladed screwdriver, slide
that out of the way.
And then inside there is the retaining clip and once again use a screwdriver, be careful
not to scratch your fork leg.
Slide the clip out of the way.
Next we're just going to go ahead and pop that seal out.
Just go ahead and firmly use it like a slide hammer and it should pop that seal right out.
Now we are going to remove the bushings, so slide your finger in, it's a split bushing.
Slide it off.
Next we're going to slide off the other bushing, and there's a flat washer in there.
The seal, you'll notice there's a sharp edge right there on the end of the fork tube, we're
going to pay special attention to that when we reassemble.
And then you have your dust seal and your retaining clip.
Please refer to part 2 for assembly instructions.