Does anyone know what the dust seal sizes are?

Thanks
 

Thanks for the how to write up. Armed with all four parts of the write up I stripped cleaned and reassembled everything in under four hours. I'm pretty sure my My 2009 bike with close to 18000km had never been done before, but in fact it was all in pretty good shape. But nice to know it's all cleaned and lubed and good for another couple of years.

I've just been following this for the last day or two.
Now, I'm no mechanic, but i have tools, a Haynes manual and an Android tablet with this page open so off I go!

Started with steering head bearings:
Handlebars off, forks off, clamps off, top yoke, bottom yoke and steering stem out.

Bearings looked in pretty good nick for 30,000 miles but the races were a little bit pitted. Will get them replaced under warranty in March.

Washed out the bearings and dryed them with a hair dryer, then packed them with marine bearing grease.

Put it all back together with a big squeeze on the lock nut and then release and a little nip up. Side to side movement is nice and smooth and no hard spots. Just right.

While I was at it, I cleaned up my front caliper and disc. New rubber grease on the sliders since one pad was wearing more than the other.

Moved on to Swingarm and Pivot points:

Followed this guide to the letter. It was all a bit daunting at first, it's cold and i immediately snapped one of the plastic pins that holds the rear shock flap in place.

But it started to make sense and became a fun challenge if you've never done it before!

https://dl.dropboxusercontent.com/u/...Image00015.jpg

Again, everything looked ok. The swingarm axle was in pretty good nick but I still rubbed it down with steel wool and greased it up.
The bearing cages came out and are now replaced with proper grease. Lost one of the pins at one point but found it with a headtorch!

In the pivot knuckle, there are 48 pins in total, that's 24 each side.

What this guide doesn't mention is the best time to re-fit the bottom chain roller.
Do this before you re-attach the swingarm. Trust me! It's a pig if you leave it til last!

Gave the whole bottom part of the engine a bloody good clean down with petrol, cleaned up the shock, around the front sprocket, anywhere i could now reach with nothing on the back.

While cleaning around the front sprocket, I noticed this:
https://dl.dropboxusercontent.com/u/...Image00014.jpg

Ordered a new set and they arrived today!

https://dl.dropboxusercontent.com/u/...Image00016.jpg

Guess what I'm doing tomorrow!!

Thank you Ohlins for a perfect walkthrough for idiots like me.
Cheers!

Yeah Weave, it's a bit of aproblem as you cannot see the sprocket with the cover in place. The next time I gat at my bike I'm gonna drill a 25mm hole in the cover so that I can see the sprocket condition.
Good job you checked.

Steve

That's why I just bought one of these too:

http://www.altechdesigns.co.uk/49-th...cket-cover.jpg

From aliwakeskake here on XT660.com

His website is: AltecH Designs

Glad you got it all done..see....wasn't so bad after all?


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Hi Ohlins , Pleiades just put me onto your guide for stripping and greasing the swing arm , shock mounts etc......great stuff , thanks for that. Makes it do able even for me! Steve

You're welcome Sir.

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This thread is great thanks heaps :grouphug5:

No problem

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