Dnepr MT9 - Fork Leg Dismantling and Assembling; Front Fork Dismantling and Assembling; Front Fork Repair

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I.
The wheels must be also checked for proper centring when re ~
placing the spokes that are bent or broken. Newly fitted spokes must
be tensioned to the same degree as the remaining spokes. If other
spokes are found to be loose, tighten th em up. ·
VIII. REPAIRING THE FRONT FORK
I. DISMANTLING AND ASSEMBLING THE FR.ONT FORK
The front fork may be subjected to partial disassembl y and re-
pairs without removing the entire fork.
Dismantling and Assembling the Fork Leg
To di s as s emble the fro nt fork leg, proceed as follows:
undo the screw in the fork leg end piece and drain the oil;
unscrew the clamp nut securing the fork leg tube to the traverse,
by s lightly pulling up the shock absorber rod, slacken the check nut
of the rod and unscrew the clamp nut from the shock absorber rod;
in s ert the front axle into the fork leg end piece and, using a ra-
dius wrench, unscrew the gland housing assembly;
remove the fork leg end piece together with the shock absorber
and spring from the fork leg tube; .
remove
the spring rings securing the lower bushing of the fork
leg tube, remove the lower bushing, take down the upper bushing · of
the fork leg tube, remove the housing together with the gland;
screw off the nut of the bridge coupling bolt by two or three
turns and take out the fork leg lube by moving it down (to facili-
tate this operation, it is permissible to screw the clamp nut on to
the end of the.iork leg lube by four- five thr eads and drive the tube
out of the traverse cone by slightly tapping it with a rubber ham-
mer).
Wash the removed assemblies and components in kerosene anq
thoroughly · inspect them, replace the defective parts, if any.
Re-assemble the fork leg in reverse order after first lubricating
the friction members with automotive engine oil. To mount the gland
housing on the tube, use a mandrel 0-4337.
When screwing the shock absorber rod into the clamp nut and
securing the rod, take care to ensure that the clearance between the
nuts on the rod and the upper end piece of the spring (axial clear-
ance) is within 0.2 and 0.5 mm.
Before screwing up the clamp nut securing the fork leg tube in
the traverse, screw up the lower screw used for draining oil from
the fork leg end piece and, from above, fill 130 cm
3
of automotiv .e
engine oil AKn-1 0 (to be used in summer) into the fork leg tube.
In the winter time, at sub-zero temperatures, use oil AK3n-6
GOST 1862-63 . .