Sachs fork service manual

2014-2016 RR (Standard model)

2013-2016 RS
 Table of contents

List of special tools…………………………………. 2

Exploded views………………………....…………… 3
Removing the front fork…………………….…… 5
Rebound valve disassembly……………………..13
Compression valve disassembly……………….19
Compression valve reassembly…………….…22
Rebound valve reassembly……………….…….25
Fork leg reassembly………………………………..30
Compression piston calibration 2T……………42
Rebound piston calibration 2T………………… 43
Compression piston calibration 4T…………. 44
Rebound piston calibration 4T……………….. 45
Torque values…………………………………………. 46
General information……………………………….. 47
 Introduction
For removal and replacement of the fork refer to the
pages in this shop manual. These procedures must take
place in a clean environment using professional tools and
some special tools.
Take special care not to damage the surface of the fork,
especially the stanchions and seal locations .

On the vice, always use protective jaws of brass or

aluminum.

Clean all parts before assembly using lint free rags or

towels as not to release fibers avoiding oil contamination.
Contamination inside the fork can affect the operation
and may cause premature wear. Always replace worn or
damaged parts.

CAUTION;
Disassembly and assembly of the fork or the incorrect
use of aftermarket parts can cause malfunctions or
serious risk to the safety of persons and property.
Therefore, before performing any maintenance, be sure
to read and follow the instructions carefully as described
in this manual.

List Special Tools CODE DESCRIPTION

005299000094 damping rod holding tool

005299000095 fork seal guide
005299000096 brass soft jaws (brass)
005299000097 seal driver 2
Exploded view

3
 legend

1 Outer tube 12 Spring washer

2 Bushing 13 Fork spring

3 Support washer 14 Spring preload ring

4 Fork seal 15 spring preload ring

5 Retaining clip 16 Right yoke

6 Dust seal 17 Set screw

7 Spring clip 18 Left yoke

8 bushing 19 Cartridge

9 Inner fork tube 20 Cartridge guide

10 Top cap 21 Damping rod

11 Preload spacer 22 Compression valve

4
Check and record the position of the
rebound adjustment.
To do so, turn the adjuster A
clockwise counting the number of
clicks until it stops(note this setting).
Then turn the adjuster fully open by
turning it counter clockwise until it
stops.

Check and record the position of the

compression adjustment.
To do so, turn the adjuster B
clockwise counting the number of
clicks until it stops(note this number).
Then turn the adjuster fully open by
turning counter clockwise until it
stops.

Unscrew the cap.

5
Secure the fork by clamping the
yoke at the axle hole in a vice using
soft jaws. Pull the outer tube down
towards the yoke.

Pull the spring down while pushing

the preload spacer up to expose
the locking nut.

While exposing the nut, install a

wrench .

6
While holding the lock nut, unscrew
the cap.

Remove the cap.

Do not unscrew the lock nut from the

damping rod.

7
Remove the spring.

Drain the oil.

Secure the fork in a vice at the

caliper hanger or axle mounting area
at a 30 degree angle.

8
Insert the damping rod holding tool
(005299000094) into the fork tube.

Firmly hold the tool in position.

Unscrew the compression assembly

from the damping rod.

Remove the compression assembly.

Warning: Oil will leak out of the fork.

Make sure to use a catch container.

9
Remove the damper cartridge assembly.

Using a small screw driver, remove the

dust seal by prying it at various points
being careful not do damage the edge
of the outer fork leg.

Remove the retaining clip being careful

not to scratch the inner fork tube.

10
Pull using two hands and remove the
outer tube from the inner .

Remove the bushing from the inner tube.

Remove the outer tube bushing and

washer.

11
Remove the oil seal.

Remove the retaining clip and dust seal.

12
Dismantling the damping rod

Remove the two spring preload rings from

the damping rod paying attention to there
orientation .

Unscrew the spring guide from the

damping rod.

Remove the snap ring with a screw

driver and pliers.
Check that there are no burrs on
the edges of the aluminum shaft
that can damage the Teflon stem
guide.
In the case there is a burr, remove
with 400 grit sand paper( limited to
the area of the burr).
13
Remove the shaft from the bottom of
the damping tube.

Remove the rebound adjuster rod from

the damping shaft.

Remove the Teflon bushing from the

rebound piston.

14
Place the soft jaws (005299000096
brass) on the damping rod shaft.

Tighten the brass jaws in a vice with the

piston facing up.

Loosen the nut above the piston while

holding the nut in place below the
piston with a wrench.

15
Remove the nut.

Remove the rebound shim stack

paying close attention to the
order of assembly!

Remove the piston.

16
Remove the bypass washers.

Remove the bypass spring

( observing the orientation).

Remove the remaining washers.

17
The rebound valve calibration is
shown in the table on page 42 for
the 2T and page 44 for the 4T.

18
Disassembly of the
compression assembly.

Lock the lower cap in a vice and

loosen the nut from the assembly.

Remove the nut with the bypass

spring.

Remove the bypass washer.

19
Remove the compression piston.

Remove the compression shim

stack paying close attention to the
order of assembly.

The compression valve calibration

is shown in the table on page 43
for the 2T and page 45 for the 4T.

20
Remove the O-ring from the
compression valve cap.

Remove the O-ring from

compression piston being careful
not to damage or scratch the seat.

21
Reassembly of the compression
valve

Place a new O-ring onto the

compression cap.

Place a new O-ring onto the

compression piston.

Install the compression piston

with the stepped edge facing
upward.

22
Place the bypass washer on the
piston.

Apply a drop of high strength

locking agent to the nut.

Install the nut with the spring

facing the piston.

23
Torque the nut to 6-7Nm.

24
 Rebound valve assembly

Install the small bypass washer.

Install the bypass spring noting

the orientation.

Install the large bypass washer.

25
While pressing the large bypass
washer and spring down with one
hand, install the compression
piston with the stepped edge
facing down until it is seated.

Install the rebound stack of

washers in the correct order(see
table on page 42).

Apply a drop of high strength

thread locking agent to nut.

26
Thread the nut on the rebound
assembly.

Torque the nut to 8-9 Nm.

Install the Teflon bushing onto

the piston. Make sure the
bushing stays snugly on the
piston. Otherwise roll it on a 8-
9mm rod to preform its shape
before mounting on the piston.

27
Insert the damping shaft into the
tube.

Install the shaft snap ring.

Screw the spring guide onto the

shaft until it stops.

28
Slide the rebound adjuster rod
into the shaft.
Note: If the rod has a taper on
one end, the tapered side
should be inserted into the
shaft.

Slide the spring support rings

onto the damping cartridge with
the beveled or chamfered side
facing down.

The spring support rings

should slide over the spring
guide and rest on the spring
support tabs.

29
 Fork leg reassembly

Apply O-ring and seal grease to

the inside edge of the dust seal.

Slide special seal installation

tool (005299000095) over the of
the inner fork tube.
The use of this tool prevents
damage to the edge of the seal.

Slide the dust seal over the tool

and onto the inner fork tube.

30
Apply O-ring and seal grease to
the inside of the oil seal.

Slide the oil seal over the tool

and onto the inner fork leg
avoiding damage to the seal
edges.

Remove the special tool and

install the metal support washer.

31
Slide the bushing over the end
of the inner fork tube.

Seat the bushing into the recess

of the inner fork tube.

Apply O-ring and seal grease to

the area of the outer fork tube
where the seals rest.

32
Carefully slide the outer tube
over the inner tube.

Use seal driver(005299000097)

to push the bushing into place.

Push or tap the bushing until it

is fully in seated.

33
Place the seal driver
(00529900097) between the oil
seal and dust seal.

Push or tap the oil seal until it is

fully seated.

Place the retaining clip into the

groove on the inside of the
outer fork tube.

Caution: Make sure the clip is

fully seated in the groove!

34
Push the dust seal into place.

Fully insert the cartridge into the

fork tube.

Apply O-ring and seal grease to

the O-ring on the compression
piston.

Apply O-ring and seal grease to

the cap O-ring.

35
With the cap threads previously
cleaned, apply a medium
strength thread locking agent to
an area 1/3 the circumference.

Insert the compression

assembly into the hole in the
fork yoke.

Tighten with a torque wrench

to 30Nm.

36
Measure out 533cc of fork oil
for the 2T and 555cc for the 4T.
With the outer tube as low as
it will go and the damping rod
slightly raised pour 2/3 of the
measured oil into the fork.

While moving the rod up and

down, pour in the rest of the
oil. Continue moving the rod
until it moves smoothly
without and gaps or surges.
Leave the leg stationary for a
couple of minutes to allow the
oil to fill the chamber between
the cartridge and allow any air
bubbles to rise. At this point
move the rod and outer fork
tube up and down together
several times through out the
stroke.
Lower the rod and outer tube
all the way and check the oil
level. Adjust the level with the
appropriate tool.

110mm for 4T
130mm for 2T

37
Slide the spring over the guide
and rod.

Pull the spring down with one

hand while keeping the rod
raised.

Install the two washers on top

of the spring then put the
wrench on.

38
Apply O-ring and seal grease to
the cap O-ring and threads. Put
the cap and spacer onto the
rod.

Screw the cap on by hand until

it stops.

Holding the nut, tighten the cap

to 10Nm with a torque wrench.

39
Pull down on the spring to
remove the wrench.

Lift the outer fork tube and

screw it to the cap until it stops.

Screw in the rebound adjuster

clockwise until it stops A. Back
it out the number of clicks
recorded to set as before.

The stock setting from the

factory is 12 clicks out for both
the 4T and 2T.

40
Screw in the compression
adjuster clockwise until it stops B.
Back it out the number of clicks
recorded to set as before.

The stock setting from the

factory is 12 clicks out for both
the 4T and 2t.

41
Compression piston calibration setting
2T

Molla = spring Rondella = shim

42
Rebound piston calibration
2t

Rondella = Shim

43
Compression piston calibration
4T

Rondella = Shim

44
Rebound piston calibration
4T

Rondella = Shim

45
Torque Values

46
 General Data

2T 4t

Spring dimension…..................… 040, 1x160mm ……… 040, 5x160mm

Spring rate ……………………………………….. .42 ……………………. .48

Oil Quantity…………………………………… 130mm………………...110mm

Oil Type……………………………. 5w Motul

Rebound clicks (From completely closed) 12 ………………….… 12

Compression clicks (From completely closed) 12 …….................. 12