| Author | Message | ||
     Jamba |
This is how i made it, sorry about my poor english Parts needed: J8138.3A8 Buell XB Slider bushing front fork 43 mm 2 pcs J8127.3A8 Buell XB 43 mm and XR1200 Front fork oil seal 2 pcs J8130.3A8 Buell XB and XR1200 Dust seal front fork 43 mm 2 pcs 46343-06 Buell and XR1200 Guide bushing front fork 43 mm 2 pcs 1 litre fork oil 15W tools needed: 32 mm socket 23 mm socket Adjustable wrench 17 mm wrench screwdriver calipers For start: 1. lift front end 2. loosen top end 32mm nut a bit, just a little 3. remove front brake 4. remove lower front fender 5. remove front wheel 6. remove tubes from tripletree There’s some no good pics, i hope you get the idea OK, take a lot of rags and somekind of bin for oil... So, tubes are now on floor. First, remove the snapring from top of preload adjuster, then remove adjuster (22mm) while holding top end nut (32 mm) There you find a washer and a piece, which has 3 pins   now remove top nut from tube with 32mm socket  Take a good hold from that metal pipe and press down, so you get a 17 mm wrench to it’s place and with 32mm socket remove top off from damper (at pic, it’s allready removed)  remove 17mm wrench and pipe under it. Turn tube upside down (above bin for oil), spring drops off. If you have progressive springs, notice which way they are... Now you may leave tubes dripping... With screwdriver (carefully) you may take off dust shield  under that there’s a lockring, remove it with screwdriver  take a good hold on both outer and inner tube. With couple of vigorous pulls they will separate from each other (my picture shows like they are bent, but that’s just my poor camera..)  this is lower end:  and same tube’s upper end with bushings  take off bushings, fist upper (thin one) and the lower pushing (thicker one), do not make scrathes…  notice now which way the old seal is! remove old stuff away and clean tubes well as any small dirt may broke your new parts… you may lube seals with silicon grease  there’s no need to put the lockring yet, just assemble new bushings, first the thick one  and do not forget to clean outer tube aswell...  then just start putting things together  thicker bushing near…  and washer  now you can press it with screwdriver bit by bit from different points till it’s at bottom  from old seal you may make an assemblingtool… cut it, and take off those metal pieces  with a wooden brick you can press oilseal to it’s place (assemblingtool is there too)… looks like i have allready had a crash..  seal is it’s place when you can see lockring’s groove (assemblytoolseal has allready removed here)  put lockring to it’s place dustshield goes in just pressing with fingers..  Press fork tubes alltheway down  i put mine to a vice so that’s straight vertically, add oil till surface is 113mm from top  now you may lift damper few times up and down, to bleed some air. Then put spring in and lift damper up with your fingers  put steel tube on it’s place and again press so that you can put your 17mm wrench there Hold on that 17mm wrench and tighten top nut to damper. Lift tube up and tighten top nut to tube (with that 32mm socket, and not too tight...) put in that piece which has 3 pins, look that pins go to their holes on top of that goes washer tighten your preload adjuster how it was (mine har 3 grooves shoving), you may lube that o-ring with silicon grease. now remember the snapring…  put things back to your bike | ||
| 7873jake |
Jamba, Your timing was perfect. I will be doing this in about another week or so (after the parts I ordered arrive) Thanks for taking the time to capture this and post it. --Jake | ||
| Ratbuell |
...and I'm getting ready to order my parts. Excellent timing!  | ||
| Cyclonedon |
I just had mine done at the dealer. Not cheap! | ||
| Ratbuell |
Had mine done at the 10k (as an employee - STILL not cheap). At the 30k? I'll do my own (not an employee anymmore). Tutorials like this are great to have handy | ||
| Cycletlh |
With mine hitting 50k and never been touched I need to do this as well. Thanks for the post. | ||
| Argentcorvid |
Hey, you should repost this in the Knowledge Vault. |
