Motobecane 40 - Fork Bushing and Spring Replacement

REPLACING
FORK BUSHINGS
AND
SPRINGS
Disconnect the speedometer cable.
Disconnect
the
front
brake control
cable.
Remove the outercas'ing
shouldered
end
of the
front
brake
cable
and
free the
cable
from
fender
support.
Remove the fork cap
retainer
nuts
(slotted
screwdriver,
No. 100012).
Remove the
wheel complete
with
fork
plungers
and
springs.
Remove the
dampers.
Remove the
fork
seals
(fig.
1).
Extract
the
bushings and
sleeves
with the Z-jaw
pu11er,
No. 100006
(fiq.2).
Insert a
new
set of
bushings and
sleeves
in
each
fork
tube.
Make sure
the
bottom fork
seals are
jn
good
condition:
otherwise
rep'l ace
them
(fjg.
3).
Fit
new
fork
springs
if
the
old ones
were
broken.
Fi
t
the
dampers
and the
fork
seal s on the
p'l
ungers
.
Coat
the springs
with
grease
and
fit the wheel
with
plungers
back
into
the
the
fork shel
I
.
Fit
the
rubber
washers,
cups,
and
t'ighten
the upper
nuts
(slotted
screwdrivero
No. 100012).
NQTE:
Make sure the
top
struts
of the
fork
plungers
are
lined
up
wjth
the
fork
housjns
before tightenihg
down on the
slotted
nut
with
Tool No.
100012
(fjq.
4
and
5).
-->
Fis.
4
g
e
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1--.t
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f!t!:Fl
Fis.
3
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R0
62
Flg.
I
Fig.2
Fis.
5