How to dismount left leg spring in the front fork ?

Hello


After many discussions here and some other forums, I know that :
- the fork is made by Kayaba (but I didn't find a part-list or repair manual related to)
- this 4 holes cap is threaded and screwed in the tube
- the tube needs to be heated to unscrew the cap
- the can be unscrewed with a tool who would look like this :



Next step for me : I will give this fork leg to the local Yamaha dealer, who knows Kayaba fork and is ready to change for me the spring.


Thanks a lot to those who answered my different posts about this subject.

Hi Vince,

yesterday I was at Wilbers Company.

To make fotos, was impossible. But I could see the man working.

I only talk about the left. He had a tool. looked nearly like this on your Pic. but on Top he could use a Ratchet.

I think they have done the tool by themself.

He needed a little bit force, to unscrew this part.

What will I say. In the left leg is only the spring, and oil. Nothing else! In the right is the Cartridge.

This spezial Screw is only to hold the spring down, and this metal rod only to hold the cap.

He filled oil until until 140 mm air chamber. both legs the same. Compressed without Spring.

The procedure needed half an hour for both legs. and was really cheap.

So, and now I will test the result. Yesterday it was raining.

Rudi

'lut

Here is the end of the operation, replacing the spring in the left leg, now that I have received the right tool to unscrew the inner cap.

Here is the upper cap, with a specific nut under it. We hold the upper cap with a 17 mm tool and need another tool to hold the lower nut


When the upper is unscrewed and the specific nut is removed, we can then use the specific tool, which goes into the holes in the inner cap


We build a 140 mm long hose, to pump up the oil in the inner tube. This will create a 140 mm air chamber, when it is only 120 mm high originally. This will give a softer fork during compression phase.


The hose and the syringe are in place. We pump up the oil until it doesn't come up anymore. The spring must be out of the inner tube.


We put the Wilbers in place, with the narrow part upside


We put back the preload system upon the spring, under the inner cap


We put back the inner cap in the inner cap, pushing on the spring


We screw the inner cap with the specific tool


We put back the small shock washer on the preload tube


We put back the specific nut on the preload tube, screwing it as much as possible, but without blocking it


Then, we screw tightly the upper cap on the preload tube


We screw back the specific nut against the upper cap


We put back the outer tube against the upper cap and screw the upper cap. We'll finish to screw it when the fork leg will be mounted back in the tees


Here are the required tools


Then, to put back the fork legs, the wheel, brakes and mudguard :
- put each fork leg in the tees,
- screw only the lower tees, just enough to block the legs
- screw the upper caps definitively on the fork leg (torque = 5 Nm)
- screw the upper tees screws (torque = 18 Nm)
- put back the ABS captor in the right leg foot, tightening also its cable
- put back the wheel, introducing the axle on the right side, don't forget the small tube on the left side
- screw, by hand, the axle nut
- screw the 4 screws in the fork legs foot (torque = 10 Nm)
- screw the axle nut (torque =63 Nm)
- put back the brake calliper on the fork leg and screw it (torque = 45 Nm)
- screw the lower tees screws (torque = 18 Nm)
- put back the mudguard on the fork legs and screw the 4 screws which hold it on the fork legs
- tighten the brake lever to apply back the brake pads on the disk

Here it is !!!