Rebuilt the forks

[Twisted]

Well I've been putting it off for a while and finally got around to ordering my fork tubes and decided to tackle it This weekend. Ended up buying fork tube assemblies(thanks Kaptain)cause I had a big nick where it rides the seals, and I already had a rebuild kit. Everything went smooth taking it apart, found it easy to separate the lowers while still on the bike, one man operation. After cleaning all the nasty gunk out of the lowers, rebuilding was a breeze too using the seal tool Th3Infamous (Eric) recomended. Then put everything back on the bike, put the front wheel back on started tightening the pinch bolts and before I even had them tight enough to break out the torque wrench, SNAP, the one pinch bolt snapped off. Looking at the bolt, it looks like was cracked for a while and decided to go.
So what started as a easier than anticipated job became a major pain in the ass. It proved not an easy operation drilling out a stainless bolt in almuminum. I tryed an easy out to no avail, then the small drill bit wondered and started biting alumimum. In the end I had no choice but to drill it out larger and put an oversized 5/16" bolt in which I had to grind down the head to fit into the recess. In the end all is back together , but what a nightmare. I'm gonna keep an eye out for a used right side lower and eventually swap it out just so it's right, but for now she's good to go.

Just wanted to say a big thanks to GasMan for his excellent how to and Th3InfamousI for the write on the tool, made life a breeze as far as installing the seal. Never tackled a fork rebuild before only swapped out triple trees, and if it wasn't for that damn bolt it would have been smooth sailing. Just have to have some good weather to test her out.

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[The Honch]

My seals starting leaking, and I'm trying to get the nerve up to attempt this myself. I usually don't do anything outside of fluid changes.

 

[Twisted]

My seals starting leaking, and I'm trying to get the nerve up to attempt this myself. I usually don't do anything outside of fluid changes.

It was easier than I thought, I was holding off no knowing what to expect, would have done it sooner if I knew.

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[The Honch]

I guess I gotta do what you did and just man up.

 

[Twisted]

I guess I gotta do what you did and just man up.

Just don't break a bolt in the sliders!!! The tool helped alot with the seals, well worth it.

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[BWG56]

I have the tool Honch, let me know when your going to do it and I'll come visit and watch

 

[The Honch]

That would be cool. I'm bare bones on tools. I've gotta start building a collection.

 

[Th3InfamousI]

Just don't break a bolt in the sliders!!! The tool helped alot with the seals, well worth it.

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Cool yes! Without that tool you wouldn't be able to change them mounted for sure. The PVC cupping works but the tool makes it much easier on my opinion. I've done both and ended up needing an extra set of hands with the PVC tool to not bang up the Lowers.

I have the tool Honch, let me know when your going to do it and I come visit and watch

That would be cool. I'm bare bones on tools. I've gotta start building a collection.

Fork seals are easy! And if Ker has the tool already why buy it when you can borrow it!

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[Th3InfamousI]

Well I've been putting it off for a while and finally got around to ordering my fork tubes and decided to tackle it This weekend. Ended up buying fork tube assemblies(thanks Kaptain)cause I had a big nick where it rides the seals, and I already had a rebuild kit. Everything went smooth taking it apart, found it easy to separate the lowers while still on the bike, one man operation. After cleaning all the nasty gunk out of the lowers, rebuilding was a breeze too using the seal tool Th3Infamous (Eric) recomended. Then put everything back on the bike, put the front wheel back on started tightening the pinch bolts and before I even had them tight enough to break out the torque wrench, SNAP, the one pinch bolt snapped off. Looking at the bolt, it looks like was cracked for a while and decided to go.
So what started as a easier than anticipated job became a major pain in the ass. It proved not an easy operation drilling out a stainless bolt in almuminum. I tryed an easy out to no avail, then the small drill bit wondered and started biting alumimum. In the end I had no choice but to drill it out larger and put an oversized 5/16" bolt in which I had to grind down the head to fit into the recess. In the end all is back together , but what a nightmare. I'm gonna keep an eye out for a used right side lower and eventually swap it out just so it's right, but for now she's good to go.

Just wanted to say a big thanks to GasMan for his excellent how to and Th3InfamousI for the write on the tool, made life a breeze as far as installing the seal. Never tackled a fork rebuild before only swapped out triple trees, and if it wasn't for that damn bolt it would have been smooth sailing. Just have to have some good weather to test her out.

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BTW- what weight did you go go with? I know we have another thread talking a out this so curious to hear your thoughts.

Sorry about the broken bolt! I know your pain! The problem with a broken bolt is drilling a grade 8 sucks ass. Although I wouldn't be to worried about the bigger bolt.

Interesting it happened putting it in, rather than removing the bolt. What torque did you use? I think pinch bolts are low , only 12ft lbs

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[The Honch]

Cool yes! Without that tool you wouldn't be able to change them mounted for sure. The PVC cupping works but the tool makes it much easier on my opinion. I've done both and ended up needing an extra set of hands with the PVC tool to not bang up the Lowers.




Fork seals are easy! And if Ker has the tool already why buy it when you can borrow it!

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I just hate being a pain in the ass, asking for a tool everytime I'm doin any work.

 

[Th3InfamousI]

I just hate being a pain in the ass, asking for a tool everytime I'm doin any work.

Well he offered to come over ! You can use it once them buy your own later

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[Th3InfamousI]

Dude , by the way awesome fucking job on the paint man! Seriously.

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[Twisted]

BTW- what weight did you go go with? I know we have another thread talking a out this so curious to hear your thoughts.

Sorry about the broken bolt! I know your pain! The problem with a broken bolt is drilling a grade 8 sucks ass. Although I wouldn't be to worried about the bigger bolt.

Interesting it happened putting it in, rather than removing the bolt. What torque did you use? I think pinch bolts are low , only 12ft lbs

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Went with the Motion Pro tool, worked great. And yeah the pinch bolts are 12 foot pounds, didnt even have that on it when it snapped.

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[Twisted]

Dude , by the way awesome fucking job on the paint man! Seriously.

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Thanks man!

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[KaptinAmerika]

The infamous................
"Why does that feel like its not tight.....*TINK*.....AHHHHHHHHH"
Such a warm fuzzy feeling

 

[cavcom278]

Wow i was thinking of doing mine next winter so when i do ill order new bolts before i start the process of changing out the seals. Oh and the paint is Killer.

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[Twisted]

BTW- what weight did you go go with? I know we have another thread talking a out this so curious to hear your thoughts.

Sorry about the broken bolt! I know your pain! The problem with a broken bolt is drilling a grade 8 sucks ass. Although I wouldn't be to worried about the bigger bolt.

Interesting it happened putting it in, rather than removing the bolt. What torque did you use? I think pinch bolts are low , only 12ft lbs

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Misread the first time, your talking oil. I ended up going with 30wt after hear a few guys that switched to 20wt and wanted to go back to 30. Actually didn't add the oil yet, ordered it with some other parts and should be here today.

 

[Twisted]

The infamous................
"Why does that feel like its not tight.....*TINK*.....AHHHHHHHHH"
Such a warm fuzzy feeling

That's exactly what happened, lmao. Didn't feel like it was getting tight at the point when it should have so I decided to back it out thinking maybe the threads were fubar and snap. Wouldn't have been so bad if it was a flush mount break but being past the pinch point I couldn't get the small bit to stay centered on the bolt. It flexed and wandered off to the side thus screwing my chances of of retaping for the 1/4 20 bolt. Thanks again for the parts Curtis! The tubes came in record time and the other parts should be here today

 

[BWG56]

Misread the first time, your talking oil. I ended up going with 30wt after hear a few guys that switched to 20wt and wanted to go back to 30. Actually didn't add the oil yet, ordered it with some other parts and should be here today.

Andrew recommended Harley's oil if there is a dealer close to you, Screaming Eagle extra heavy

 

[Twisted]

Andrew recommended Harley's oil if there is a dealer close to you, Screaming Eagle extra heavy

Is that the same as 30wt? Have some Bell Ray 30wt fork oil coming today

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