2003 D
Duke S
SL A
Air &
& U
U-T
Turn S
Service G
Guide
R
EV
. A
3
6. Using a plastic mallet, firmly tap the rebound damper shaft bolt and air/U-Turn spring shaft
bolt until both shafts are free from lower leg. You will feel the shafts release from the lower
leg press-fit. See Fig 5. With the oil pan below the fork, remove both shaft bolts.
7. Firmly pull lower legs down. You may need to tap the top of the brake arch lightly with a
rubber mallet to release the shafts from the lower leg. Oil will drain into the oil pan.
Using a lint-free rag and isopropyl alcohol, wipe the upper tubes clean of oil and
contamination. Inspect the upper tubes for wear. If anodization is worn from upper
tubes, the crown/steerer/upper tube assembly should be replaced (fig. 7).
N
OTE
:
SET THE LOWER LEG ASSEMBLY RIGHT SIDE UP IN AN OIL PAN TO ALLOW THE
EXCESS OIL BATH TO DRAIN
.
8. Using a 24mm socket wrench, loosen and remove the air top cap (left side). To remove
the U-Turn spring assembly go to step 18. Inspect the top cap o-ring for wear. Replace if
worn or cut. Clean the underside of the top cap with isopropyl alcohol (fig. 8)
9. You may find removal of the snap ring easier by positioning the fork horizontally.
10. Remove the snap ring from the upper tube: the white spring assembly base plate is
spring-loaded with a wavy washer against the snap ring. Press the white base plate in
toward the upper tube with a flat hex wrench or flat head screwdriver to allow the
snap ring to be removed. Press against the white base plate while removing the snap
ring (fig. 10).
5
7
8
10
R
E M O V I N G T H E
H
Y D R A
A
I R
S
P R I N G
A
S S E M B L Y
