168 replies to this topic

[jht]

A dismantling option saving the teflon bushes. http://www.carpe-tdm...;hl=fork teflon

Knocked a jig up and tried this with both my sets of forks, one set old & manky other set effectiveley brand new

Didnt work

ended up doing the std slide hammer method on newer forks

old ones are waiting for liberal application of oxy-acteylene

[Taras]

A dismantling option saving the teflon bushes. http://www.carpe-tdm...;hl=fork teflon

That method didn't work for me. Inner tube was going out but oil seal was still there, so bushes were overlapped.

To save the bushes I used oil pressure method described earlier. I extended fork for about 10 centimeters, filled it up with oil, closed top cap, covered seal area with some rag to avoid oil fountain and tried fork compressing with strap. It was very inconvenient, so I invented new way -



Just pushed that construction to make it straight and oil seal came out easily with minimal oil spillage.

[3vd]

Aha, I may try this when I come to do the mkI.

Cheers!

[dapleb]

To save the bushes I used oil pressure method described earlier.

That won't save yer bushes as you still need to get lower bush over upper bush.

[Taras]

That won't save yer bushes as you still need to get lower bush over upper bush.

I wasn't sure if I need to extract them. Expected to change only oil seal.

[dapleb]

Still trying to work out if you are a giant or just a low garage.

[3vd]

I've finally got around to changing the fork seals on the MKI.

I've removed the forks and used the oil fill method to pop the seal out, had to beat the shit out of it with my sledge hammer! This popped out the seal and the top bush. The top bush looks fine to me so I'm guessing the bottom bush will be fine also so I could fit the new seal and pop it all back together...... but I want to repaint the fork legs as the paint is crap.

So how the feck do I undo the bolt up the bottom of the fork leg, which holds the damper?

I need a looooonnnnggggg socket, what size? Anyone?

[Studley Ramrod]

The damper rod bolt is an allen socket head type, I used a long allen socket in my drill. Press down on the fork tube to help stop the damper rod moving when you undo it.

[dapleb]

used the oil fill method to pop the seal out, had to beat (it) out of it with my sledge hammer!

Hmm I must have missed this bit of the Bjorge method.

[3vd]

The damper rod bolt is an allen socket head type, I used a long allen socket in my drill. Press down on the fork tube to help stop the damper rod moving when you undo it.

I've tried that but it just spins.

I can see a large hex nut jobbie inside the fork leg, so assuming I can get a very long socket type thing made up at work I should be able to get it loose, but I need to know the size of it.

Anyone happen to know?

[ChrisG]

I found an electric impact driver on the Allen bolt did the job by smacking it fast enough the cartridge doesn't have time to move.

[dablik]

Okay i know this is gonna sound stupid,, but,,,,,,,,,,,,,,,,,,,,,,,,,,did'nt someone stick a broom handle or a piece of copper pipe to hold the cartridge still

[dapleb]

Okay i know this is gonna sound stupid,,

Tats wan way of doin it dabbers. Though I have never had trouble undoin em....doin em ooop however oi have to implement some cunning.

[wicklamulla]

Okay i know this is gonna sound stupid,, but,,,,,,,,,,,,,,,,,,,,,,,,,,did'nt someone stick a broom handle or a piece of copper pipe to hold the cartridge still

yes i did this yesterday and it worked just fine.

[Studley Ramrod]

yes i did this yesterday and it worked just fine.

Wicky, what size was the tool you used fer removing the bolt ? Or is a mk2 bolt different to the mk1 wan.

[wicklamulla]

Wicky, what size was the tool you used fer removing the bolt ? Or is a mk2 bolt different to the mk1 wan.

Ian, i have socket type allen keys which are further lengthened by adding an adaptor thingy which 'steps down' (A REDUCER????) the sizing so they fit my ratchet. I can take a photo if you need it. the length of wooden broom handle i use is rounded off so it provides enough contact/friction when pressed down on top the damper thingy, then i use the allen key to loosen the allen bolt. Easy to do if ya put the broom handle down into the fork and then invert it and press down on the broom handle using yer body weight and then undo the bolt......mind you if it's uber toight you may struggle.




ps. i dunno if the MKI setup is the same as my mk2.

Edited by wicklamulla, 27 May 2012 - 09:19 pm.

[Studley Ramrod]

T'were fer Maximus I were asking Wick. Thankyou very muchly

I managed to undo/refit the mk1 bolts relatively easy with a leccy drill, whilst squishing the forks with the spring still in and forks full of oil. Far easier than separating the forks which were a fookin' mare.

[dapleb]

Photos reinstalled from gallery bodge back into initial post.

[tdm850rider]

I'm glad I came across all 7 pages of this...
Recall my saying I was considering redoing the front forks myself this year?

Procrastination has served me well for once because after reading all the pain and agony I decided...

To let SOMEONE ELSE do it!







Yeah... that's the ticket, someone else.

[dapleb]

Good move but you "missed out" on the pickled onion water Thomas. Oi can send thee a wee sample so you don't feel left oot.