Fork work time

As mentioned in a previous post I was planning to do some fork work this winter. I finally decided Gold valves and Sonic springs was the way I would go. Valves came in today so time to get the old stuff out and get it ready for the new stuff.

I made a newer fork spring compressor last fall and used it a couple of weeks ago. Made from scrap around the garage, works awesome and basically free.
A little heat was needed to get the stock compression and rebound valves out of the cartridge. Filed the peening off the valve holders and the old stuff came off easily. Ran the nut and the holders through a tap and die to remove any burrs.
I have the suggested stack info from Racetech and another set from another member. Now I just need to decide what stacks I will install.

I have some time because It will probably take a couple of weeks for the springs to make it up here from Sonic. If anyone who has done this as well has any stack info on what they used I would love to hear it.

NICE ! What springs did you end up buying ?

Hi there, that's a really nice setup you have!! Good on ya' my man!!

I might have ya beat on a cheapie homemade spring compressor...

Behold, the bar clamp and scrap aluminum spring compressor!

I find it strange, that there is so many that is not satisfied with the fork.
If I would change something on the suspension on the S10, it would be the rear suspension. I'm missing the compression adjustment...
I think the fork work near perfect for me.
(2017 non ES)
But nice tools, and workshop, I wish I had a place like this.

You are not wrong.
I would agree the shock is so much worse than the fork. As soon as I bought my tenere I was looking for a fix with the shock. Way too low and soft in the rear. I was relatively happy with the fork.
I fixed the rear last year with a used aftermarket shock and immediately the fork showed it needed work.

Lifting the rear up with the shock puts lots more weight on the front and it immediately became very harsh. I waited till this winter to do something, hopefully it will be better come spring.

I am sure something else will need work next winter.

RC I had a very similar compressor made out of a clamp as well. Worked well.
I came across a pic showing a company with nice unit using a bottle jack on the bottom. Only issue was it cost over $300.00 .

I thought I can make that, and after finding those tubes in the recycled metal bins at work I had most of my stuff. Bottle jack is from a shock spring compressor I made a few years ago. I can just switch the jack back and forth as needed.

Bottle jack is the way to go. So easy to operate.

I have 2 more sets of tubes in the corner. When I have time I plan to make a couple more. I have a few guys I used to club race with that want to buy it.

Here is a pic of the unit I saw for sale. It is a very heavy unit and can do shocks or forks in the same tool which is very nice but pricy.

JMZ I went with 0.95kg springs. Hope they are not too stiff.

Ah I see you already done the rear shock "thumbs up"

jrusell said:

RC I had a very similar compressor made out of a clamp as well. Worked well.
I came across a pic showing a company with nice unit using a bottle jack on the bottom. Only issue was it cost over $300.00 .

I thought I can make that, and after finding those tubes in the recycled metal bins at work I had most of my stuff. Bottle jack is from a shock spring compressor I made a few years ago. I can just switch the jack back and forth as needed.

Bottle jack is the way to go. So easy to operate.

I have 2 more sets of tubes in the corner. When I have time I plan to make a couple more. I have a few guys I used to club race with that want to buy it.

Here is a pic of the unit I saw for sale. It is a very heavy unit and can do shocks or forks in the same tool which is very nice but pricy.

Click to expand...

I love the bottle jack idea. I would have had to buy the square tubing, though. When I made mine (after seeing a photo of a commercial version on line), I did it "Apollo 13" style: Can I build this from junk I have laying around the garage? The answer ended up being "no", as I thought I had some 1/2" threaded rod and I didn't. It works well, and it's easier for me to control over a ratchet strap version, but the bottle jack I'm sure works a lot better.

jrusell said:

JMZ I went with 0.95kg springs. Hope they are not too stiff.

Click to expand...

Only one way to find out, LOL . I`m sure you will like them.

Too cold to work in the garage today, and I had some races to watch.
At least I managed to get some work done.

Springs came in last week, so with the temp finally above zero I figured I should get off my butt and put my forks back together.
Hopefully I will be happy with the result, but probably another month or more before I get the bike on the road and test them.
0.95kg springs, 5wt oil, 150mm oil level(+-470ml),
I plan to get the forks on the bike tomorrow and then move on to whatever is next on the list.

RCinNC said:

I might have ya beat on a cheapie homemade spring compressor...

Behold, the bar clamp and scrap aluminum spring compressor!

Click to expand...

NOBODY beats my spring compressor for cheap-ass ness.

Behold, spreader clamp and paracord:

There seems to be some very creative work arounds to front fork disassembly. This one started out as a rear shock collar removal tool I made for my Honda 750 and got modified for the Tenere.

I can already see that yours wouldn't work for me, BWC...I don't know how to weld. It's definitely a skill I should acquire.

I love the paracord idea, though I think I'd replace the paracord with steel wire and hooks. I've seen paracord break when it was used as suspension lines on T-10 parachutes; one out of 30 breaking wasn't a big deal, but one out of one breaking on a fork spring compressor could produce an interesting Youtube video.

I can't speak for anyone but me, but my inspiration for the homemade compressor was pretty much, "you want how much for that compressor tool?? No freaking way!", and it was off to the scrap bin.

This was my solution, a couple of sash clamps, used it loads of times.

RCinNC said:

...I love the paracord idea, though I think I'd replace the paracord with steel wire and hooks. I've seen paracord break when it was used as suspension lines on T-10 parachutes....

Click to expand...

Break? Pfffft. The clamp releases with a trigger. You can't ease it off - you pull the trigger, the clamp lets go all at once.

It sounded dramatic enough that my wife came out to see WTF I was doing.

Go big or go home! Honey, hold my beer....watch this!

Are these ST fork springs really that hard to compress? I have always been able to remove those nuts, cap and spring while pushing down on the spring by hand. Last few fork rebuilds I just pay a suspension shop to do it. My time costs way more than the few hundred bucks they charge to service front and rear suspension.

And watching these procedures reminds me of how messy of a job it is.