Fl Front Fork

INSPECTION PROCEDURE (Early 1977 and Earlier)

If hydraulic fork does not work properly; that is, if it leaks oil or lacks original snubbing action, check the following before disassembling.

OIL LEAKS FROM VENT HOLE. If oil leaks from vent hole in upper bracket bolt (2, Figure 2-35) and filler screw (38, Figure 2-36) when fork flexes, check for over-filling. Drain and refill with exact amount of oil.

If oil leaks from vent hole in upper bracket bolt when fork tubes contain correct amount of oil, check breather valve in upper bracket bolt or hole. To replace breather valve, place bolt in vise and tap back three stake locks with small punch and hammer. Pry valve from recess with length of stiff wire. If unable to free valve, drill hole in valve larger and pry valve out with small pin or screwdriver. In some cases, it is necessary to drill and tap hole in valve and pull it out with tap. Insert new valve assembly and stake three spots on bolt lip

If fork action is stiff or soft and spongy when breather valves are functioning and oil content is correct, damper valves in fork tubes are inoperative. Fork must be disassembled. If fork is submerged in water, oil must be replaced at once. Water will rust damper tube valve parts. In neglected cases, the valves may stick and result in almost no snubbing action.

If oil bypasses slider tube bushings and leaks at top of sliders, bushings are worn and must be replaced To replace slider bushings, fork must be disassembled. If slider bushings are worn, water will contaminate oil. Oil will appear emulsified, aerated and light brown

If fork slider has play on slider tubes, bushings are worn and must be replaced. Fork must be disassembled. However, it is not necessary to disassemble entire fork and steering head unless desired.

INSPECTION PROCEDURE (Late 1977 to 1978)

If the hydraulic fork does not work properly or an appreciable amount of oil leakage should develop, inspect the fork as follows:

Check the oil level in each fork side by completely draining and refilling fork as described in "Changing Fork Oil." Be sure correct amount of oil is used to refill fork tubes. An insufficient or excess supply of oil will result in faulty recoil action. When draining oil, check for signs of water in the oil. Oil will appear emulsified, aerated or light brown in color. Leakage of oil from forks would indicate replacement of seals and O-rings is needed. See "Disassembling Front Forks."

1. Bracket clamping bolt (2)

2. Upper bracket bolt and oil seal (2)

3. Fork tube cap (late 1977 and 1978)

4. O-ring (late 1977 and 1978)

5. Spring

6. Screw (late 1977 and 1978)

7. Washer (late 1977 and 1978)

8. Shock absorber tube (late 1977 and 1978)

(late 1977 and 1978)

10. Spring (late 1977 and 1978)

11. Sleeve (late 1977 and 1978)

12. Fork tube (late 1977 and 1978)

13. Fork slider (late 1977 and 1978)

14. Lock ring (late 1977 and 1978)

16. Washer (late 1977 and 1978)

17. Lockwasher

18. Fork stem nut

19. Upper bracket

20. Head bearing nut

21. Dust shield

22. Lower bracket and stem

23. Bearing cone (2)

24. Bearing race (2)

Figure 2-35. FL - Non-Adjustable Fork - Exploded View

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