Did the front end this weekend. Took as many photos as I could but its a bit of a pain considering some of the steps come close to requiring three hands.
Here we go
Front end off the bike from the previous break down
You should have taken a ride height measurement before this point but if you didnt this is your last chance to get the reference measurement so you can return the bike back to the geometry it had.
Forks on the bench and ready for a service
Document the settings
These forks have a pressurized bladder similar to a shock
These are twin chamber forks so loosen the inner chamber but dont completely back it out before taking the cartridge out
Now for the outer chamber.
You should now be able to slide the outer tube down
Now back out the the lower bolt
Now youll have to compress the spring so the metering rod sticks through the lower end of the fork and use the cartridge holding tool to hold it in place.
Now compress the spring and pull out the tool. Be careful here because if you slip it could fire the cartridge out of the top of the fork.
One free cartridge
Now remove the dust seal and snap ring for the oil seal.
You should now be able to slide hammer the forks apart
On to the cartridge.
If you loosened the inner chamber before removing the cartridge from the fork then this come apart easy.
Remove the compression valving
Time to go to the wash tank
Clean and ready for inspection
Lay everything out to be sure you have it all. Forks generally have pairs of everything
Put the rebound valving back into the chamber
Fill with oil and bleed
Install the compression valving and pressurize
When done your cartridge should look like this
On to the outer tubes
Some seal grease
Inner tube ready for new seals
O-ring for a travel indicator
Time for seals and bushings
A little grease in the outer tube to help the bushings and seals slide into place
Drive the seals in using a seal driver and a soft faced hammer
Ready to go
Assembly is pretty much the opposite what was done to disassemble
Now put a specified amount of oil in the outer chamber
Close the tube and set the clickers