e. Carefully slide with wheel downward out of the brake caliper.
2. Remove the brake caliper from the fork leg (6mm hex key).
3. Loosen the fork caps (Cobra 37mm Fork Cap Tool).
4. Remove the fork legs from the triple clamps (5mm hex key).
5. One leg at a time:
a. Remove the fork cap from the fork tube.
b. Lower the fork tube to expose the fork spring.
c. Pull the fork spring down from the fork cap to expose the damper rod
lock nut. Secure this nut using a 14mm wrench.
d. With the 14mm wrench on the damper rod nut, use the 37mm fork cap
wrench to free the fork cap from the damper rod.
e. Remove the 14mm wrench and allow the damper rod to fall into the
cartridge tube.
f. Remove the fork spring.
g. Invert the fork to allow the oil to drain. Pump the damper rod assembly
several times to help any excess oil trapped in the cartridge to drain.
Assembly procedure
1. Completely collapse the outer fork tube onto the stanchion tube. Add enough
2.5 wt. Bel-Ray fork oil to fill the cartridge tube. Pump the damper rod up and
down slowly to help the assembly fill with oil.
2. Once the cartridge assembly is bled, continue to fill the fork with oil until it is
120mm +/- 2.5mm from the top of the fork.
3. Install the fork spring.
4. Use a flexible retrieving tool to pull the damper rod up through the fork spring
and thread the damper rod into the fork cap.
CAUTION:
Ensure that the fork cap is completely threaded onto the damper rod before it
makes contact with the lock nut.
5. Pull the fork spring down from the cap and torque the damper rod lock nut to
15 N-m (11ft-lb) with a 14mm wrench.
CAUTION:
The damper rod is hollow and will break if the nut is over tightened.
6. Ensure that the fork cap o-ring is in good condition, Use the 37mm fork cap
wrench to secure the fork cap to the fork outer tube. Torque the fork cap to 20
Nm (15 ft-lb).
7. Pump the fork leg several times to verify that it operates smoothly.
8. Install each leg back into the triple clamp. Torque each pinch bolt to 11N-m (8
ft-lb) making sure both legs are set to the same height in the clamps.
9. Reinstall the brake caliper.
10. Reinstall the front wheel.
1. Install axle through non-brake side fork lug and wheel hub
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