forks

[clay18]

i know this question has been ask a few times but i cant seem to put it all together, what do i need to rebuild my front forks? i have new progressive springs and fork seal.

[MiCarl]

Fork oil

 

Service manual

 

17mm hex drive socket

 

Torque wrench

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I'd put new bushings in while I was at it. They're inexpensive and you'll have brand new forks. Besides, nothing worse than starting the job and finding out it's gotta all lay around for a week because the bushings are shot and you had to order them.

[Ozlander]

Fork oil Service manual 17mm hex drive socket Torque wrench

 

Gotta have more than that. Gotta take the handle bars off, remove the calibers, loosen the axle clamp and remove the axle.

[gscbertrand]

Don't forget the front fender.

[clay18]

where did you find the bushings?

 

Fork oil

 

Service manual

 

17mm hex drive socket

 

Torque wrench

----

 

I'd put new bushings in while I was at it. They're inexpensive and you'll have brand new forks. Besides, nothing worse than starting the job and finding out it's gotta all lay around for a week because the bushings are shot and you had to order them.

[Rocket]

where did you find the bushings?

 

OEM or from Racetech......

 

Also the damper rod will need a 15/16th head bolt with nuts locked to bolt & socket with a few extentions (alternate method used by some, is a broom handle) to hold it still if not using an impact gun with the bottom hex bolt on removal. There should be a writeup in the 1st gen tech library.

[warthogcrewchief]

I just rebuilt my forks and I got the copper washers for the main bolt on the bottom of the piston, the lower and the upper bushings, the oil seals, and the dust seals from bike bandit.

 

However, if you call Rick at buckeyeperformance.com, he has a kit that has EVERYTHING you need to rebuild the forks (minus the tools, oil and progressive springs).

 

Also, when you rebuild your forks, use Mobil 1 5w-30 full synthetic as it will increase the life of your forks and create a better ride.

 

I order to hold the lower piston in place so you can remove the bottom bolt (after you remove the top cap and spring), you'll need a to make a tool.

 

The tool is made from the following items:

- two, 2-foot steel pipe, 1/2 inch diameter, threaded; one pipe cut in half (got mine at Ace Hardware and they even cut it for me!)

 

- a steel "T" for the threaded ends of the pipe

 

- a bolt that has a 24mm head

 

- J.B. Weld or access to a welder.

 

To install the oil seal, I used a two foot section of 1 1/2" PVC pipe.

 

Here is a link on this forum for step by step on the rebuild...wish I had this when I did mine!

[ame=http://www.venturerider.org/forum/showthread.php?t=496]Fork Seal Replacement - VentureRider.Org[/ame]

 

Below are pics of the "tool" I made to hold the piston in place. If you decide to make the tool, I recommend having someone weld the bolt instead of using JB Weld, as the JB Weld started to break when I removed the piston.

 

The other option is to use an air impact wrench to remove the bolt. When installing, be sure NOT to use an impact gun as the torque specifications for the bolt is low.

 

 

Overall view of the "tool" to hold piston in place while removing lower bolt:[ame=http://www.venturerider.org/forum/showthread.php?t=496]http://i19.photobucket.com/albums/b160/warthogcrewchief/100_0831.jpg[/ame]

 

Close-up view of the Bolt end of the tool:

http://i19.photobucket.com/albums/b160/warthogcrewchief/100_0832.jpg