We categorize procedure as advanced, only undertake this if you are a competent mechanic with access to the correct tools and working environment. If you are in any doubt please ask a professional to perform this process for you.
1/ Remove air-valve dust cap and let the air out of the fork.
2/ Using a 27mm socket, un-screw the air plug and then completely remove the plug and air tube from the station.
3/ Using a 1.5mm hex key, remove the rebound adjuster
4/ Using a 5mm hex key, remove the RH foot nut
5/ Using a 12mm socket, remove the LH foot nut
6/ Separate the upper assembly from the lowers
7/ Remove the dust seal external springs and remove the dust seals. NOTE: Removing the dust seals makes refitting the upper assembly easier.
8/ Once the dust seals have been remove re-fit the external springs (removing the springs prevents damage to the seal).
9/ Using cir-clip pliers remove the cir-clip from the base of the air leg and remove rod assembly.
10/ Remove the disc from the base of the leg, this is a tight fit and may require tapping off with a small hammer.
11/ Remove negative spring.
12/ Install travel spacer and push until you hear an audible click.
13/ Re-install the negative spring and push until you hear an audible click.
14/ Re-install the disc to the bottom of the rod, again this may need tapping down with a small hammer.
15/ Re-install the rod in to the base of the stanchion and re-install the cir-clip. NOTE: Check the cir-clip seating and make sure it’s fully in its groove.
16/ Install the dust seals on to the stanchion and re-fit the upper assembly. BE CAREFUL! Make sure the stanchions do not tear the oil seals as the stanchions pass through them.
17/ Re-fit both foot nuts and torque to 10NM + or – 1NM.
18/ Re-fit the rebound adjuster and secure using the 1.5mm hex key.
19/ Press the dust seals back in to the lower legs.
20/ Invert the air tube and place 25ml of 7.5w oil inside.
21/ Invert the fork and re-install the air tube. NOTE: You will need to tap the air tube in with your hand to get it past the piston head on the rod assembly, as the tube goes in the pressure inside it will increase so make sure you expel the air to make installing easier.
22/ Using the 27mm socket re-fit the air plug and torque to 20NM + or – 1NM
23/ Re-inflate to your desired pressure
24/ Check travel.
Part numbers for travel change spacers:
536181 = 20mm spacer
536216 = 10mm spacer
CR model: the procedure is pretty much the same except that the air tube in the CR is not removable.
|350R internal for reference only|