Sherco Fork Seal Replacement

Sherco Fork Seal Replacement
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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.
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Fork Parts Overview, 2003 Sherco Parts Book, p.32
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Fork Seal Replacement
Remove the headlight or the number plate.
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).
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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.
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2” (50mm)
3 bolts
2 bolts
Using a 5mm Allen wrench, loosen the 3 lower triple clamp bolts and
the 2 upper triple clamp bolts.
Sherco Fork Seal Replacement
Slide the fork tube down as
shown, leaving about 2” (50mm)
of it exposed above the lower
triple clamp.
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5mm Allen
wrench
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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.
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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.
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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.
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Use a small screwdriver to
remove the fork seal circlip.
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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.
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Drain the fork oil into a suitable container.
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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.
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Photo 20 shows the
lower fork leg removed. The
dust seal and the oil seal
will remain on the fork
tube.
Sherco Fork Seal Replacement
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.
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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.
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Reassembly
Fork Tube Assembly
“Cone”
Lower Fork Leg
With the “cone” installed on the bottom of the fork tube assembly, insert it into the lower fork
leg.
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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.
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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.
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Install the New Seal
Sealing Lip
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.
Sherco Fork Seal Replacement
Seat the new
seal into the lower
fork leg by hand
using constant,
even pressure
around the
perimeter of the
seal.
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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.
Install a new
“Dust Seal,” and then
use the RYP fork seal
driver to also fully
seat it into the lower
fork leg.
Once the seal is
fully seated, reinstall
the seal circlip.
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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.
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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.
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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.
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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.
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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).
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Using an 8mm Allen wrench, tighten the lower
fork bolt to 17 ft lbs.
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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.
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Final Touches
Reinstall the headlight or the front number
plate and the job is finished.
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