RD Fork Overhaul

AW: RD Fork Overhaul

the slit up steel spacer is actually in the diagram.why is it slit up?

the plastic pieces are directly placed under the top nut?
 
Why not?

It's fairly typical of a spring spacer. Some have a split up the side, some don't. You can use almost anything as a preload spacer. I have steel tube in lots of different diameters in my shop, plus I have some PVC around the shop. Pretty much ever set of forks I work on gets a new spacer for more preload than they originally had. When I sit on the bike, I like no more than 1" of sag from full extension in the forks.
 
AW: RD Fork Overhaul

do you have a special move to reposition the top nut?

so i guess i as a fork noob would use just elbowgrease to push down the spring with the pvc preload...and then torque the nut.
 
My rule of thumb is that if you have enough preload, it's a motherfucker getting the nut back on. :)

I wrap a leather glove around the tube, and clamp it in a vice. (Don't use a rag. The vice will fuck up your fork tube right through the rag.) Put the right size socket on a 1/2" drive ratchet, do some grunting, yelling, and swearing until you get the nut pushed down and started.

Progressive makes a fork spring compressor tool. That's for pussies.
 
Te original spacer is not so much "split" as is it "rolled and not welded". With all that extra preload it may be hard to get the top nut started, so be careful to avoid cross threading it.

Mount the fork tube in the triple clamps and tighten the bottom clamp bolts (not the top) to hold the forks vertically so you can press down on the top nut.
 
teazer said:
Mount the fork tube in the triple clamps and tighten the bottom clamp bolts (not the top) to hold the forks vertically so you can press down on the top nut.
Click to expand...

You'd want to be sure that you don't knock the bike over. :D
All too often, there are things in the way that can make it difficult to do this on the bike.

I should do a video some time on how I do this. Guaranteed to be entertaining watching the fat old fuck popping a vein putting a fork plug in.
 
AW: RD Fork Overhaul

alpha your my hero:)

there def be some grunting in downtown vienna!

when i removed the top screw of one fork the preloaders seem to were stuck in the fork tube...after carefully using a mallet it got out.

i realised there are some grains in the tube that seem to keep the inside from sliding.
clean it with a rag and kerosene?
 
I wonder if the PO made the plastic spacers slightly large so he could press/hammer them into place to get the top nut on.
 
Everything should be clean, and grit free. Kero is good for cleaning, or WD40, or carb cleaner.

I buy WD40 in a gallon can, and put it in a trigger spray bottle. Cheaper than buying aerosol cans.
 
AW: Re: RD Fork Overhaul

teazer said:
I wonder if the PO made the plastic spacers slightly large so he could press/hammer them into place to get the top nut on.
Click to expand...

there are no plastic spacers in the diagram but the steel spacer seems smaller then original...i guess i will use 2 pvc and the steel spacer...i think when i just use the pvcs the preload is too small and the fork will be saggy...

is it normal that the fork springs are more tight above then below...maybe the PO built in progressive springs with an aftermarket kit of spacers..
 
teazer said:
I wonder if the PO made the plastic spacers slightly large so he could press/hammer them into place to get the top nut on.
Click to expand...

More likely that it is just a coincidence that it's a tight fit.
 
AW: RD Fork Overhaul

so i got the seals out...finally...it was impossible to get them out with a seal puller so i tried wd 40 waited...and waited nothing happened then i had the idea to slightly torch the outside of the fork...without touching the seal.

...after 10 seconds i saw the gook running down between seal and alu...a bad sticky mixture out of old oil and dirt....they popped out easily.

yty5yzej.jpg


now im waiting for parts...

as for rebuilding the seals amd stuff:

my work order would be:

1.)clean all parts,grit free

2.)insert plunger back in fork tube

3.)install the bottom screw with washer

4.)put in seals,lubricate before with fork oil

5.)fill in 135 cm3 of 15w fork oil

6.)grunt and press in preload with spring

7.)torque top nut

8.)being totally exhausted but happy :)

ebuba9ez.jpg


Question: do you install the seals before you put in the fork tube and.torque the screw on the bottom or the other way around?
 
I tend to instal the new seal with the fork tube in place. I put a length of PVC over the tube, and the fork tube helps to center and guide the seal into place.
 
I do it with the legs out and use a suitable large socket to press the seal back into place nice and square.
 
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