04 AXEL SERVICE MANUAL Page 15 REV NC
Bushing Installation (CONT.)
4. Slide weighted handle onto end of threaded rod and tap rod into casting with rubber Mallet
until proper depth is achieved. If using depth gage, slide gage onto rod before installing
weighted handle and let it settle on of Mandrel. Tap rod until appropriate line on gage is even
with top of casting leg.
5. Remove weighted handle and gage (if applicable).
6. For sizing of the lower bushing:
7. Use slotted top cap from sizer kit and set it into the top of the casting leg, straddling the
threaded rod. Spin the extra nut with washer down to the top cap and using a wrench,
socket, or speeder wrench, tighten the nut in a clockwise direction. This will cause the
Mandrel to be pulled through the bushing, thus sizing it. Keep turning the nut until the tool is
all the way through the bushing and can be pulled out of the leg.
8. To install top bushings, repeat steps B-E. Note that the top bushing gets inserted until it stops
against the step inside of the casting. The extra sleeve that comes with the sizer kit is used
to space the top cap off of the casting, so that there is enough room to pull the sizers out of
the casting without bottoming on the cap.
9. If you find that the bushings are too tight after installing them, use the sizer Mandrel that does
not have a stop on it to hold the bushing while installing it into the casting. This is available in
the 25.4mm leg kit (85-5191) to go back in and resize the bushings.
10. To resize bushings, Choose the next larger size rings and repeat the above process.
11. When satisfied with the results, reinstall Dust/wiper seals and then reassemble fork
