Fork Disassembly & Seal Replacement

[Flyin W]

Need some input please : - Without scanning 40 or 50 pages to see if anyone has discussed this, I thought I'd post a new note. Has anyone torn down their forks beside me? Has anyone bought or tried the Yamaha 90890-01441 YM-01441 OEM spring compressor tool? I replaced my seals and oil then installed some new Race Tech 1.0 springs. I made my own spring compressor tool from the diagram in the service manual which worked ok. I was going to order the Yamaha unit if they weren't too expensive. Thought I'd check to see if anyone had tried one out to see how it worked. Also is "A" on the fork spring guide up or down? :question: Hah!

PM's welcome - Thanks for the input, Wardy

P.S. The heavier fork springs work great for aggressive riders especially when used in conjunction with the 4 over Eibach shock spring, also available from Race Tech. Back end don't sack down when loaded heavy giving you that chopper look and handling. Makes it a little harder to touch the ground tho. ::008:: (me: 5'7" @ 200lbs)

 

[avc8130]

1.0s at 200lbs? Put a zip tie on your fork leg and let's see how much travel you are able to use.

ac

 

[Flyin W]

I can bottom it with the front brake lever. That's how I found out my preload spacer was to long. I've been bottoming forks since 1970 and have became very good at it. I'm surprised the more hard core off roaders haven't complained more about it. I ride a lot of gravel back roads but have touched down more on the wonderful Oklahoma paved roads than doing doubles. MW

 

[greg the pole]

ya, traxxion dynamics on ebay is the way to go. $45 dollars to your door,
and here's my write up: http://thetenerist.wordpress.com/2012/12/26/fork-rebuild/

 

[Flyin W]

Thanks,
Yup the handy dandy ratchet tie downs are required. The OEM shows screwing inside the plastic collar but the tool I made threads inside the coils of the spring.

I'll check them out, haven't priced the Yamaha svc manual tool yet. Appreciate it, MW

 

[Mchaskell]

Greg,
Nice write up and photos.

 

[greg the pole]

Greg,
Nice writup and photos.

thanks,

more to come, I just had to replace my rear drive shaft seals, had some tools made up, as the ones that Yamaha lists are simply not available for purchase...
The traxxion dynamics can be sucked down with a single strap, works very well

 

[snakebitten]

Re: Fork Disassembly & Seal Replacement

I can bottom it with the front brake lever. That's how I found out my preload spacer was to long. I've been bottoming forks since 1970 and have became very good at it. I'm surprised the more hard core off roaders haven't complained more about it. I ride a lot of gravel back roads but have touched down more on the wonderful Oklahoma paved roads than doing doubles. MW

"Hard Core" would kind of be bragging a bit, but I do most enjoy standing and hanging on to this big beast while the suspension is getting stressed holding up 800lbs.

But with OEM forks, they usually packed up on the big stuff and I didn't find it very easy to bottom them out. They went from too mushy to too non-compliant and back. Over and over. (Didn't mind them much on tarmac. They hid their shortcomings in that environment)

After upgrading, they are far more consistent\linear. And I can get them set to where they bottom on a really big stroke. I think I'm running a .95 spring. Sounds soft, but I guess the damping must be setup to work with it.

One other thing. I never remember "hearing" my oem forks during the stroke. If I'm off the gas and catch a good bump or dip, I hear the hydraulics in them now.

 

[avc8130]

I can bottom it with the front brake lever. That's how I found out my preload spacer was to long. I've been bottoming forks since 1970 and have became very good at it. I'm surprised the more hard core off roaders haven't complained more about it. I ride a lot of gravel back roads but have touched down more on the wonderful Oklahoma paved roads than doing doubles. MW

Do you have a zip tie on your fork leg?

If that is the case, you are in dire need of damping help.

ac

 

[avc8130]

To compress the springs I use one of these and a ratchet strap:

http://www.harborfreight.com/3-way-edging-clamp-4067.html

ac

 

[Flyin W]

Ouch! That looks painful and dangerous.