When replacing or maintaining hydraulic valves, keep the following points in mind:

1. Ensure you have proper personal protection at all times because escaping fluid from a hydraulic pressure leak can damage your eyes, penetrate the skin and cause serious injury. [2]

2. Take precautions to assure the absolute cleanliness of the hydraulic oil, as even small amounts of dirt or foreign materials in the system can cause wear or damage to components, as well as general faulty operation of the hydraulic system. [2]

3. If there is a hydraulic system failure, drain and flush the entire system and replace the filter cartridges. A complete oil change must be made under these circumstances. [2]

4. Check the magnets in the hydraulic reservoir for metal particles whenever the hydraulic system is drained. If metal particles are present, flush the entire system and add a new change of oil. [2]

5. Use absolutely clean containers and funnels when handling hydraulic oil. [2]

6. Cap and tag all hydraulic lines involved when removing any hydraulic component, and plug the ports of the removed components. [2]

7. Disassemble all hydraulic components in spotlessly clean surroundings. Clean all metal parts in a clean mineral oil solvent, ensuring all internal passages are thoroughly cleaned. [2]

8. Replace all O-rings and seals when overhauling any component. Lubricate all parts with clean hydraulic oil before reassembly, and use small amounts of petroleum jelly to hold O-rings in place during assembly. [2]

9. Replace any lost hydraulic oil when completing the installation of the repaired component, and bleed any air from the system when required. [2]

10. Keep all hydraulic connections tight. [2]

11. Before working on the hydraulic system:

• Lower forks to the ground.
• Engage parking brake.
• Shut down the engine.
• Clean area around reservoir cap.
• Loosen reservoir cap.
• Remove key from starter switch. [1]

12. Use a piece of cardboard or paper to search for leaks. Do not use hands! Before disconnecting lines, be sure to relieve all pressure. Before applying pressure to the system, ensure that all connections are tight. Do not apply pressure to a damaged line, hose, or fitting. [1]

13. Change filters annually, or more often depending on operating conditions. [3]

14. Maintain a sufficient quantity of clean hydraulic oil of the proper type and viscosity in the hydraulic reservoir. [3]

15. Samples of hydraulic oil should be drawn from the reservoir and tested annually. These samples should be taken when the oil is warmed through normal operation of the system. [4]