When purchased, the forks on this Puch wouldn't compress. So they were dismantled to find the problem. Once freed up, they leaked oil badly because the stanchions were corroded, so parts were ordered to make them good again.
The first thing is to remove the fork springs by undoing the 4 bolts holding the handlebars and clocks and undoing the fork top bolt with a 24mm spanner.
After the front wheel and mud guard have been removed, the fork legs can be removed from the bike by releasing the lower fork clamp bolt and pulling the fork downwards.
To remove the lower fork leg from the stanchion, the nut on the bottom needs to be removed using a 10mm socket. A slotted screwdriver will be needed to hold the damper rod from turning as shown.
A piece of angle iron can be used to hole the lower fork leg if it is drilled with two 8mm holes 44mm apart. Then the mud guard studs can hold the fork leg in place. A large spanner can be used to unscrew the top cap of the fork containing the seals.
With the top cap removed the fork stanchion can be slid out of the lower fork leg.
The bushes should be checked for wear and the stanchion for corrosion.
To replace the seals it is necessary to remove the bushes and the top cap.
To remove the bushes a 24mm spanner can be used on the damper valve housing.
The stanchion should be held in the vice soft jaws by the larger diameter /re-enforced part of the stanchion.
The image above shows the damper valve assembly parts laid out in order.
If a new seal is fitted it should be orientated as shown here...
...followed by a new felt washer orientated as shown here.
Felt washer correctly fitted.
The original or replacement bushes need to be fitted before the damper rod and spring are inserted into the stanchion, followed by the valve assembly.
A washer and sealing O-ring were fitted to the end of the damper rod with the washer orientated as shown, to protect the O-ring from being crushed.
If needed, new rubber buffers are available for the lower shrouds.
With the bellows refitted, the fork legs can be put back on the bike and each leg filled with 110cc of 5W fork oil.
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