Step 1

Thread one of the 5/8" Nuts onto the threaded rod, deep enough to allow you to clear the lower bushing. Install Sleeve followed by Extractor and the second 5/8" nut as shown.

Step 2

Clamp your Bushing Extractor Assembly in a soft-jawed vice. Insert your lower leg assembly onto the Bushing Extractor Assembly  past the upper and lower bushing until Sleeve sits flush with lower leg.

Step 3

With your 24mm wrench, turn the lower nut counterclowise until bushings are pushed out.

Step 4

Unthread nut and remove Extractor, and sleeve. Extracted bushing will be inside of the sleeve.

Step 1

Install the correct Installation Tip and Guide Ring based on the Fork family. The Installation Tip and Guide Ring are engraved with fork family. Install Guide Ring first (with the small diameter end closest to the installation Tip), then the Installation Tip. Use a 8mm allen to tighten the M10 screw until the Installation Tip is sercured into the shank.

Step 2

Find the appropriate bushing depth, once determined, use the Spacer Combinations to set up proper depth. Slide Spacers over the M12 bolt in the handle.

*Note: While a lower leg may be listed as being introduced in a specific model year, that part may be used across various model years going forward. While not listed specifically by model year, your fork may fall under the listing for the previous most recently introduced similar version of the lower leg.

You can also verify which lower leg you are working on by measuring the location of the original bushings before removal. Compare your measurement to the table to verify correct lower leg bushing position.

Step 3

Use a 19mm Socket to screw the M12 bolt into the shank portion of the tool. Once the Spacers are installed, the depth can be verified by measuring from lip on the Installation Tip to the lip of the Guide Ring. Insert the Hammer Cap onto the Handle. The tool is now assembled. 

Step 4

Place the lower bushing on the Installation Tip and insert the bushing into the lower. Note: Orient Bushing slits toward each other for lower legs with rear facing bypass channels. Orient the Bushing slits away from each other for lower legs with inward facing bypass channels.

Step 5

Slide the Guide Ring into the wiper bore at the top of the fork lower until the Guide RIng bottoms out on the top of the fork lower. Using a mallet, drive the bushing into the fork lower. The bushing will be at its depth once the handle of the tool makes contact with the top of the Guide Ring. 

Step 1

Install the correct Installation Tip and Guide Ring (with the small diameter oriented toward the installation Tip) based on fork family. Install Guide Ring first, then the Istallation Tip. Use a 8mm allen to tighten the M10 screw until the Installation Tip is secured into the handle.

Step 2

Once the Installation Tip and Guide Ring is installed, the depth can be verified by measuring from the tip of the Installation Tip to the lip of the Guide Ring. Note: All upper bushings require a depth of 16mm. NO SPACERS REQUIRED. Insert the Hammer Cap into the Handle. The tool is now assembled.

Step 3

Place the bushing on the Installation Tip and insert the bushing into the lower leg. Note: Orient Bushing slits toward each other for lower legs with rear facing bypass channels. Orient the Bushing slits away from each other for lower legs with inward facing bypass channels.

Step 4

Using a mallet, drive the bushing into the fork lower. The bushing will be at its depth once the handle of the tool makes contact with the top of the Guide Ring.