The Ohlins forks are a popular choice among motorcycle enthusiasts for their superior performance and adjustability. However, regular maintenance is essential to keep them in top condition. One of the maintenance tasks that might arise is splitting the forks. This process allows you to access the internal components of the forks for cleaning, inspection, and replacement if necessary.
Step 1: Gather the Necessary Tools
Before you start, make sure you have all the tools required for the job. You will need a set of hex wrenches or Allen keys, a torque wrench, a suspension fluid pump, a fork cap wrench, a fork seal driver, and a seal bullet. It’s crucial to use the correct sizes and types of tools to avoid damaging the forks during the disassembly process.
Step 2: Loosen the Axle and Lower Triple Tree
Begin by removing the front wheel and loosening the pinch bolts on the bottom of the lower triple tree. Next, loosen the axle pinch bolts and remove the axle. Once the axle is out, you can slide the forks out of the triple tree, allowing them to hang freely.
Step 3: Remove the Fork Caps and Drain the Fluid
Using the fork cap wrench, remove the fork caps to access the internal components. Be cautious as there might be residual pressure inside the forks. Slowly release the pressure and let the suspension fluid drain into a container. Ensure that you dispose of the used fluid properly in accordance with local regulations.
Step 4: Disassemble the Forks
With the fork caps removed and the suspension fluid drained, you can proceed to disassemble the forks. Follow the manufacturer’s instructions to remove the internal components, which may include the damping rod, seals, and bushings. Take note of the sequence and orientation of the components for reassembly later.
These are the first steps to splitting Ohlins forks. It is important to be patient, meticulous, and follow the manufacturer’s instructions throughout the process. By splitting the forks and carrying out routine maintenance, you can ensure that your Ohlins forks continue to provide optimal performance and enhance your riding experience.
How to Split Ohlins Forks
Splitting Ohlins forks is an essential process for maintaining and repairing your motorcycle’s suspension system. It allows you to access and replace internal components, such as seals and oil, ensuring optimal performance and longevity of your forks.
Tools and Materials Needed
Before you begin, gather the following tools and materials:
- Ohlins fork cap wrench
- Socket set
- Torque wrench
- Fork oil
- Seal driver
- Seals and bushings kit
- Fork dust covers
- Fork seal cleaner
- Fork oil level gauge
Step 1: Preparation
Start by securing your motorcycle on a stand and removing the front wheel. This will provide better access to the forks and prevent any accidents or damage to the bike. Make sure to wear protective gloves and goggles throughout the process.
Step 2: Loosening the Fork Cap
Using the Ohlins fork cap wrench, loosen the fork cap in a counterclockwise direction. Be careful not to completely remove it at this stage, as it may be under pressure from the fork spring.
Step 3: Draining the Fork Oil
Position an oil drain pan beneath the forks and carefully remove the fork cap, allowing the fork oil to drain completely. Once the oil has drained, reinstall the fork cap loosely to prevent any foreign objects from entering the fork tubes.
Step 4: Removing the Forks
Now, you can remove the forks from the triple clamps. Loosen the pinch bolts on the lower clamp and slide the fork tubes out of the clamps. Use caution to avoid scratching or damaging the fork tubes during this process.
Step 5: Disassembling the Forks
With the forks removed, it’s time to disassemble them. Start by removing the fork spring, followed by the fork internals, such as the damping rod and rebound assemblies. Take note of the order and orientation of the components as you remove them for easier reassembly later.
Step 6: Replacing Seals and Bushings
Inspect the fork tubes for any signs of wear or damage. If necessary, clean the tubes using a fork seal cleaner. Replace the seals and bushings using a seal driver, following the manufacturer’s instructions. Ensure that the new seals and bushings are properly lubricated before installation.
Step 7: Reassembly and Refilling
Reassemble the forks in the reverse order of disassembly. Make sure all components are properly aligned and torqued to the manufacturer’s specifications. Refill the fork tubes with the recommended fork oil, using a fork oil level gauge to achieve the correct oil level.
Step 8: Final Checks
Before reinstalling the forks on the motorcycle, make sure to check for any leaks or abnormalities in their operation. Test the forks’ compression and rebound to ensure they are functioning correctly. Once satisfied with the forks’ performance, reinstall them onto the triple clamps and tighten the pinch bolts.
Following these steps will help you effectively split Ohlins forks and maintain the performance of your motorcycle’s suspension system. Remember to refer to your motorcycle’s service manual and consult a professional if you are unsure about any steps in the process.
Step-by-Step Guide
Splitting Ohlins forks is a delicate process that requires precision and attention to detail. Follow these steps to ensure a successful fork split:
| Step 1: | Start by removing the front wheel from your motorcycle. This will give you better access to the fork assembly. |
| Step 2: | Next, you need to loosen the lower fork clamp bolts. Use a socket wrench to release the tension and remove the bolts completely. |
| Step 3: | After removing the lower fork clamp bolts, you can move on to removing the upper fork clamp bolts. These are located on the top of the fork assembly. |
| Step 4: | Once all the clamp bolts are removed, gently slide the fork tubes down and out of the triple clamp. Be careful not to damage any parts during this process. |
| Step 5: | With the fork tubes removed, you can now separate the fork legs. Carefully pull them apart, making sure to keep the parts organized and prevent any mix-ups. |
| Step 6: | Inspect the fork tubes and legs for any signs of damage or wear. If necessary, clean them thoroughly and replace any worn-out parts. |
| Step 7: | When reassembling the forks, make sure to apply a thin layer of fork oil to the tubes and legs. This will help with smooth movement and prevent friction. |
| Step 8: | Finally, carefully slide the fork tubes back into the triple clamp and tighten the clamp bolts. Use a torque wrench to ensure proper tightening. |
Following these steps will allow you to successfully split Ohlins forks and perform any necessary maintenance or repairs. Remember to always refer to the manufacturer’s instructions for your specific model to ensure proper handling and safety.
Required Tools
Before you begin the process of splitting your Ohlins forks, make sure you have the following tools on hand:
1. Fork Cap Tool
You will need a fork cap tool to remove the fork cap from the top of the forks. This tool is essential for accessing the internal components of the fork.
2. Socket Wrench Set
A socket wrench set is crucial for loosening and tightening the bolts and screws that hold the forks together. Make sure you have a variety of socket sizes to fit different bolts on your forks.
3. Fork Seal Driver
A fork seal driver is necessary for installing new fork seals after the forks have been split. This tool helps you properly seat the seals into the fork tubes, ensuring proper functioning of the forks.
4. Torque Wrench
A torque wrench is essential for tightening the bolts and screws to the manufacturer’s recommended torque specifications. This tool helps prevent over-tightening or under-tightening, which can damage the forks.
5. Fork Oil
You will need fork oil to lubricate the internal components of the forks. Make sure you have the correct type and viscosity of fork oil recommended for your specific forks.
Having these tools on hand will ensure that you have everything you need to safely and effectively split your Ohlins forks. It’s important to follow the manufacturer’s instructions and take all necessary precautions when working on your forks to avoid any damage or injury.
Preparation
Before you begin the process of splitting your Ohlins forks, there are a few steps you need to take to ensure a smooth and successful disassembly. Follow these preparation steps to minimize the risk of damage and make the process easier:
Gather the necessary tools
Make sure you have all the tools required for the disassembly process. This will typically include a socket wrench set, Allen wrenches, a torque wrench, pliers, a rubber mallet, and possibly a fork oil level tool. Check the Ohlins manual for the specific tools recommended for your fork model.
Clean the working area
Clear a clean and well-lit area to work on your forks. Make sure the surface is level and free from any debris or dirt that could potentially contaminate the fork components. Have a rag or paper towels handy to clean any excess oil or dirt as you work.
Secure the bike
To ensure stability and safety during the disassembly process, it is essential to secure your bike properly. Use a front paddock stand or a securely positioned bike stand to lift the front end of the motorcycle off the ground. This will prevent the bike from falling or tipping over while you work on the forks.
Additionally, it is recommended to place a block or wheel chock behind the rear tire to prevent the bike from rolling backward while the front end is lifted.
By following these preparation steps, you will be ready to begin the process of splitting your Ohlins forks with confidence and minimize the risk of any mishaps along the way.
Splitting the Forks
Splitting the Ohlins forks is an important maintenance task that should be done regularly to ensure optimal performance and longevity of your motorcycle’s suspension system. This process involves disassembling the forks into their individual components, inspecting them for wear and damage, and replacing any worn or damaged parts.
Step 1: Preparing the Forks
Before splitting the forks, it is important to clean them thoroughly to remove any dirt, debris, or contaminants that might be present. This can be done using a mild detergent and warm water, followed by drying the forks thoroughly with a clean cloth. Once the forks are clean and dry, they can be prepared for disassembly.
Start by removing the front wheel and brake calipers, if necessary, to provide better access to the forks. Next, loosen the fork caps and relieve any pressure by gently pumping the forks up and down a few times. Then, using a suitable tool, remove the fork caps completely and set them aside.
Step 2: Disassembling the Forks
With the fork caps removed, the next step is to disassemble the forks. Begin by removing the fork tubes from the triple clamps or lower fork legs. Depending on the specific model of your motorcycle, this may require loosening or removing additional bolts or screws.
Once the fork tubes are free, slide them out from the upper and lower fork legs. Be careful, as the fork tubes may still contain residual oil, which can spill out during this process. Set the fork tubes aside in a clean and secure location.
Next, separate the upper and lower fork legs by removing any bolts or screws that hold them together. This will allow you to access the internal components of the forks, such as the damping cartridges or springs.
Step 3: Inspecting and Replacing Parts
With the forks split into their individual components, carefully inspect each part for wear, damage, or signs of leakage. Pay close attention to the condition of the fork seals, bushings, and O-rings, as these are common areas of concern. If any parts are found to be worn or damaged, they should be replaced with new ones to ensure the proper functioning of the forks.
Additionally, this is an opportune time to clean and inspect the internal components of the forks, such as the damping cartridges and springs. Ensure that they are free of dirt, debris, or any other contaminants that might affect their performance. If necessary, clean these parts with a suitable solvent and wipe them dry before reassembly.
Once all the necessary inspections and replacements have been made, reassemble the forks in the reverse order of disassembly. Ensure that all bolts and screws are tightened to the manufacturer’s specifications and refill the forks with the recommended amount of fork oil. Finally, reinstall the fork tubes into the triple clamps or lower fork legs and tighten them accordingly.
Splitting the Ohlins forks might seem like a daunting task, but with the right tools, knowledge, and attention to detail, it can be done successfully. By performing this maintenance procedure regularly, you can ensure that your forks are in optimal condition for safe and enjoyable riding.
