this manual is designed to provide the sherco owner with...

Sherco Fork Seal Replacement 1

www.shercousa.com www.sherco-moto.com

Sherco Fork Seal Replacement

This manual is designed to provide the Sherco owner with instructions on how to replace the fork seals on 1999 – 2003 series Sherco 0.8, 1.25, 2.0, 2.5 and 2.9 models.

These instructions will demonstrates fork seal replacement in the right fork leg only, since the procedure is the same for both forks.

If you have any questions about the procedure, please call Ryan Young Products at 1-800-607-8742.

For your safety, we recommend that safety goggles be worn while performing these operations.

http://www.rypusa.com/html/contact_us.html






Fork Parts Overview, 2003 Sherco Parts Book, p.32



Fork Seal Replacement

Using a 4mm Allen wrench, remove the 2 bolts that retain the front fender to the fork, with 4mm allen wrench (the 2003 models require a 5mm Allen wrench).

Remove the headlight or the number plate.



Remove the Front Wheel

Make sure that there is at least 1/8” (6mm) of free play between the brake pedal and the stop on the frame.

With the bike supported so that the front wheel is raised off of the ground, use a 10mm box end wrench to loosen the 2 front axle pinch bolts.

Using a 10mm Allen wrench, unscrew then pull out the front axle. Remove the front wheel and set it aside.



Using a 5mm Allen wrench, loosen the 3 lower triple clamp bolts and the 2 upper triple clamp bolts.

3 bolts 2 bolts

2” (50mm)

Slide the fork tube down as shown, leaving about 2” (50mm) of it exposed above the lower triple clamp.



5mm Allen wrench

Air bleeder cap

Using a 5mm Allen wrench, tighten the 3 lower triple clamp bolts.

Unscrew the fork air bleeder cap.

Using a 22mm Allen wrench or an appropriately sized spark plug socket (as shown), remove the fork cap.



The above photos show removal of the fork cap, spring spacer, and spring, respectively. Remove these 3 parts and set them aside in a clean area.



Using a small screwdriver, pry up the dust seal and slide it up from the lower fork leg.

Photo showing the dust seal removed from the lower fork leg.

Use a small screwdriver to remove the fork seal circlip.



Remove the bolt from the bottom of the fork leg. This can be quickly done using an air impact tool fitted with an 8mm Allen socket.

Drain the fork oil into a suitable container.



Stabilize the bike with one hand, while grasping the lower fork leg. Raise and lower the fork leg along the fork tube as though it were a “slide hammer” to separate the lower fork leg from the fork tube. This process may require several strokes and a quick downward pull in order to achieve the separation.

The seal will slide out of the lower leg as shown in this photo. Note the “sealing lip up” orientation of the old seal on the fork tube, as the new seal must be installed in this same position.



Photo 20 shows the lower fork leg removed. The dust seal and the oil seal will remain on the fork tube.

Photo 21 shows the “installed” location of the “cone” which will “fall” into the bottom of the fork leg when the fork leg is removed from the fork tube.



Clean and Examine all Components

This photo shows what the fork tube assembly should look like when it is removed from the bike, with the fork and dust seals removed from the fork leg.

Examine all of the components and replace anything that shows excessive wear, damage, or nicks. Clean all of the components with contact cleaner and prepare them for reassembly.

Using a 5mm Allen wrench, loosen the 3 lower triple clamp bolts, then slide the fork tube completely out of the triple clamp.



Reassembly

“Cone”

Fork Tube Assembly

Lower Fork Leg

With the “cone” installed on the bottom of the fork tube assembly, insert it into the lower fork leg.



Washer

Use an 8mm Allen wrench to reinstall the bolt that attaches the lower fork leg to the fork tube assembly. Examine the lower fork leg bolt washer and replace if damaged. Tighten the lower fork leg bolt by hand, applying the final torque later in the process when the fork leg assembly is tightened within the triple clamps.



This photo shows the fork assembly held vertically and the use of a RYP Fork Seal Driver to drive the fork tube components into the lower fork leg.

The fork tube components must be driven down far enough to allow the fork seal to be seated and the circlip to be installed.

Apply a layer of electrical tape to the top perimeter of the fork tube in order to protect the new fork seal from damage as it is slid down upon the fork leg.



Install the New Seal

Lubricate the inside of the new seal with fork oil and slip it on the fork tube as shown. The sealing lip should face up as shown.

Sealing LipSeat the new

seal into the lower fork leg by hand using constant, even pressure around the perimeter of the seal.



Install the Dust Seal

Use the RYP fork seal driver to fully seat the new seal into the lower fork leg. The seal must be installed below the groove which retains the seal circlip.

Once the seal is fully seated, reinstall the seal circlip.

Install a new “Dust Seal,” and then use the RYP fork seal driver to also fully seat it into the lower fork leg.



Fill with New Fork Oil

Pour the oil into the fork tube. When all the oil has been poured into the tube, hold the lower fork leg and slowly “pump” the fork tube up and down several times.

Measure 330cc of Maxima 5 wt Fork Oil into a suitable container. Should you have any questions about using a different oil, please contact Ryan Young Products.

http://www.rypusa.com/

https://secure.rypusa.com/prodpage.cfm?Cat_Selected=5&SubCat_Selected=33&Product_Selected=157



Reassemble

Reinstall the fork spring as shown, followed by the fork spring spacer.

Reinstall the fork tube cap. Do not fully tighten this cap until the fork tube assembly is completely reinstalled in the triple clamp.



Install the assembled fork tube into the lower triple clamp as shown. Position the top of the fork tube about 2” (50mm) above the triple clamp.

Using a 5mm Allen wrench, temporarily tighten the 3 lower bolts as shown.

Using the appropriate spark plug socket as shown (or a 22mm Allen wrench), tighten the fork tube cap to 15 ft lbs. Do not over tighten the cap.

Reinstall the air bleeder cap. Examine the small rubber O-ring and replace if damaged.



Finishing Steps

Scribed line on the fork tube

Using a 5mm Allen wrench, loosen the 3 bolts in the lower triple clamp and slide the fork tube into the upper triple clamp. Slide the tube into the clamp so that it is in the exact same height as the other fork tube. On this bike they are both located on the lower of the 2 markings on the fork tube.

Using a 5mm Allen wrench, tighten the 3 lower triple clamp bolts and the 2 upper triple clamp bolts to 8 ft lbs. each.



Reinstall and tighten the front fender mounting brace bolts using a 4mm Allen wrench to 6 ft lbs. (the 2003 models require a 5mm Allen wrench).

Using an 8mm Allen wrench, tighten the lower fork bolt to 17 ft lbs.



Install the Front Wheel

Clean, grease and reinstall the front axle and wheel. Using a 10mm Allen wrench, tighten the front axle to 37 ft lbs.

Using a 10mm box end wrench, tighten the front axle pinch bolts to 8 ft lbs.



Final Touches

Reinstall the headlight or the front number plate and the job is finished.

this manual is designed to provide the sherco owner with...

Documents