| Author | Message | ||
     Dasbuell |
Greetings... In my youth I did all my own wrenching as it was difficult to find anyone who did work on Bridgestone motorcycles. (Yep... they used to make some pretty fast bikes in the late 60s... early 70s). Didn't have a service manual but had a box of tools. I was (and still may be) too stupid to know better on some projects, but I always got things working. To the point... to refresh my skills... because of more than a few years with no space to do any bike work and insufficient tools... I now have a pretty fair shop... more $$$ in tools than I want to think about. So I have been working on buds bikes to freshen my skills as I didn't have any projects of my own. I have a 1987 Yamaha FZ600 tinker bike to use as a nothing to lose project. The forks are leaking at the seals and I am considering doing the fork rebuild this winter. If it were my XB I'd send them off... but this is an opportunity to learn by doing. If this is done by me and it goes well... I'd feel I'd have the experience to do my XB when the time comes. What cha think... should I... or are forks left best to rebuild services. I intend to use the bike for informal drag runs to work on reaction time (ET runs are not my goal... the idea is to just to see if I wanna someday do a tuber drag bike as a money pit)... and/or a track day bike I won't worry about laying down. My goal is to spend as little as possible in case I don't like the drag/track day thing... or at my age break a hip falling in the shower. 1. Have you rebuilt forks? 2. After doing so did you ask yourself "WTF was I thinking?" 3. Any bad experiences with rebuild services. 4. Anything else ya think I should know or you want to share. THANKS!!! (formerly dasxb9s - still learning just how stupid I can be, and realizing there is no limit) | ||
| Bartimus |
I've rebuilt conventional forks many times, theres really nothing to it. Just take your time, follow the manual, and make sure you fill with the proper amount of oil. Too much oil, or the wrong weight will make them stiff, too little, will make them way too soft and cause them to bottom out or worse create cause you to crash. A little common sense goes a long way. I've never rebuilt a set of these new fangled "upside down" forks, but feel they too, should be fairly straight forward. Good luck, I think you should go for it. After all, you said the Yamaha was a "tinker bike" so tinker away!  | ||
| Smoke |
follow instructions carefully and you shouldn't have any problems. digital cameras are the •••• for unfamiliar or first time attempts.{too bad i always forget the camera and have to figure things out anyway} like bartimus said, oil amount and viscosity are very important. i've never had an fz, but it should be very similar to all the rest. good luck. tim | ||
| Dasbuell |
I have a digital camera I use for shop projects... better than notes or my failing memory!! Except for the time I forgot to use it??? DUH!!!! (formerly dasxb9s - still a slow learner) | ||
| 1313 |
If you do decide to have your forks rebuilt, I would NOT recommend White Brothers! Rebuilding forks and shocks is something that has always made me a little timid (mainly due to expensive special tools needed), so I decided to let White Brothers (I thought they were the WP suspension experts in the US...) rebuild the forks on my S2. I was quoted a 4 week turnaround time (longer than I had hoped for, but I had the spare time) and shipped my forks to them on the Friday before Good Friday. I tracked the package and they arrived at White Brothers the Monday after Good Friday. I finally received the forks near the end of May beginning of June with just enough time to get the S2 back together for the BRAG Bringing it Home event. To top things off, occasionally the right fork appears to seep/weep a little fluid. 1313 | ||
| Rick_a |
Take your time and carefully read the service manual. Forks are easy. | ||
| Bluelightning |
Rick, Are the "special" tools really needed to do the inverted forks? I have done conventional forks in the past ans they were easy, but it's time to go through my X-1's front and I'm in the same boat of deciding what to do as I don't have access to these "specialty" tools that are called out in the service manual. | ||
| Dasbuell |
I know on the Yamaha there is a special tool needed. I can make it by taking a 19mm bolt and attaching the end with threads (threats... DUH!!) to a "T" handle, using the hex end to fit into a 19mm socket like recess. This locks the tube from spinning while I remove a hex key from the bottom of the fork. Some of the special tools can be made MUCH cheaper than buying the factory tool. (formerly dasxb9s - still buying tools) (Message edited by dasbuell on August 25, 2004) | ||
| Bluelightning |
I might have to break out the welder and dust off the peanut (you know, the one collecting dust between my ears) and figure something out then. | ||
| Henrik |
Conventional forks are fairly straight forward. Operating room cleanliness is a good idea. To get the bolt holding the damper rod out, leave the forks assembled, including springs. Then, preferably with an impact driver, take that bolt out. After that, you're free to disassemble. The pressure from the spring can keep the damper rod from spinning, making it much easier to remove said bolt. Other than that, you may consider a new set of springs. Stock springs are said to last a few years at best. I always go to Traxxion Dynamics for all suspension needs. Solid, quality work by people who ride and care. They've always been on time, and often gone above and beyond. That's worth every penny they charge. Henrik | ||
| Twodogs |
I redid my "upside-down" S-3 forks last year with conventional tools w/out a manual to confuse things. The main trick I taught myself was to insert a small screwdriver into the holes of the spring sleeve and"unscrew" the spring load to remove the retainers...the rest was clips and screws. Go slow and be methodical. DOG | ||
| Twodogs |
henrik, you're right on the money about conventional dissasembly.An impact takes those stubborn dampener bolts out nicely most times.  | ||
| Keith |
I've rebuilt conventional forks and have serviced my XB's forks. If you take the time to read the manual and have the correct tools for the job, it's not that difficult. Keith | ||
| Rick_a |
You can get most fork service tools from most major aftermarket outfits...like CCI, Drag Specialties/Parts Unlimited, Lockhart, etc. I've never tried to improvise with tools doing forks... | ||
| Dasbuell |
Some of the tools are really simple... just not common... so the cost is VERY high because very few are made and tooling expenses need to be covered in the price. For the Yamaha it is simply the head of a 19mm bolt. The tool, if you can find one, is expensive compared to a bolt welded or otherwise attached to a "T" handle. It simply holds a piece from rotating while a allen head screw is removed from the bottom of the forks. Some tools can safely, cheaply, and easily be made that are just as good as the factory tool. It is hard to justify a once used tool that is $60.00 or more, when you could get the whole thing done for $150.00... or make a tool that works just as well for a few bucks. The deal is being thoughtful enough to know when a improvised or home made tool can be used, and when the factory tool MUST be used. Stop by my shop... you will see I am not afraid to spend the bucks on quality tools. I have even bought tools to work on buds bikes, I at the time did not otherwise need and did the work only for beer. (formerly dasxb9s - still figuring when to buy the good stuff and when the improvised can do) | ||
| Dasbuell |
By the way... I want to go to MMI so bad I can hardly stand it... I am trying to figure out how I can do it after I retire (I can retire next year) and make all my bills and manage the house I just bought in MO from AZ. Plus be available for my 15 year old son that lives with his mother. So I am jealous of you Rick_a. NOT FAIR... NOT FAIR... NOT FAIR!!! (formerly dasxb9s - still immature | ||
| Spike |
While we're on the subject of fork repair/rebuilding; what fluid are you guys using in your XB's front end? The manual calls for Harley's "Type E" fork oil. Anyone tried anything else? Mike | ||
| Rick_a |
Dennis..there's nothing to be jealous of...I'm a broke-••• myself. About MMI...you pick up some tips from instructors...and it helps you get into a factory dealership...other than that...it's hard to justify the expense. There's little else you need than an appropriate service manual for anything with the exception of hi-po work. | ||
| Henrik |
I get my fork oil from Traxxion. They can advice you as to which weight to run. Henrik | ||
| Keith |
I too use tools and fork oil from Traxxion Dynamics. I'm very pleased with the results. Keith | ||
| Starter |
It's not that hard. Just a couple of tips, use plenty of fresh oil to lube seals etc when reinserting, make sure you get all the old crap out, and keep plenty of plastic bags handy to use as storage and condoms to slide the tubes through the seals without risking taking small nicks out of the soft rubber. Take your time, follow the manual. |
