Fork rebuild hack... For those with judgement as poor as mine.

[Benjamin1031]

I was worried when I saw that my forks were seaping. I had fork rebuild anxiety. I knew the day would come when I needed to rebuild them and today it finally happened.

My main worry wasn't about figuring out how to rebuild my forks. I can usually figure out most mechanical things. It was knowing that I needed special tools that I'm too cheap to buy...

For the record, I WILL NEVER OWN A SPRING COMRESSING APPARATUS OR A 43mm SEAL DRIVER.

I only own one bike, my s10. When I die I will be able to count the times I've redressed my forks on one hand. With this in mind I can't bring myself to buy tools that would only ever have one purpose. No matter how "cheap" they are.

So this post is for guys like me. Guys who want to work on their own ride and don't want to have to buy one time use tools.

The first tool "they tell you that you need is a spring compressor thingy. Nay nay, I say. I used a piece of 550 cord about 4' long. Tie one end around a coil of the spring and the other end opposite side of the spring on another cool. Holding the top of the fork step into the loop like a stirrup and the cord will pull the spring down (with the bottom of the fork on the ground). Experiment before applying full force it can get ugly in a hurry... Trust me.

Next item the seal driver. When putting the new oil seal on the lower fork leg put the old one on just before. So the old oil seal is between the new one and the dust seal. Use the lower fork leg to gently drive the new seal in then simply cut the old one off. It worked like a dream!!

I didn't take any pictures since I was working alone and wasn't really sure if any of it would work in the first place. My apologies.

I hope this helps another frugal s10 driver.

If you scoffed at this post and rolled your eyes feel free to not post your critique. I got the job done. Haha

 

[snakebitten]

You won't get eye rolls from me Benjamin! Nothing but respect.

 

[OldRider]

A piece of pvc pipe can always be turned into a fork seal driver.

 

[bob dirt]

I did mine on my '12. I used ratchet straps and a vice to compress. Don't remember any problems. It was pretty easy. I had to make a special tool for my Big Wheel 350's though. I hammered a piece of square tube until it would grab onto the nut down inside the fork tube. I also had to make a special tool to take apart the clutch on one of my Polaris sportsman's. I like the challenge...usually . I always like to hear stories of DYI's. ::008::

 

[Benjamin1031]

I did mine on my '12. I used ratchet straps and a vice to compress. Don't remember any problems. It was pretty easy. I had to make a special tool for my Big Wheel 350's though. I hammered a piece of square tube until it would grab onto the nut down inside the fork tube. I also had to make a special tool to take apart the clutch on one of my Polaris sportsman's. I like the challenge...usually . I always like to hear stories of DYI's. ::008::

I had to post my triumph over this project here because all of you guys who read these threads are the only ones who would understand.

 

[Cycledude]

With fork bottom clamped in a vice I used ratchet straps to compress it, and even with the special tool from Traxxion it still took 2 people. I would love to see a video showing how u did it all by yourself with just a rope.

 

[ace50]

A piece of pvc pipe can always be turned into a fork seal driver.

::008::

I take the length I want, maybe 1½' (usually smaller diameter that will work) and split it into 4 quadrants.
Put on tube with a couple rubber bands to hold together and tap seal down!

 

[baisleyde]

Is a fork spring compressor recommended because the springs on this bike are really heavy duty ? I rebuild the forks on my MX bikes all the time , no special tools.

 

[Pterodactyl]

A local specialty shop charges $60 to rebuild a front fork and lets me provide the parts. Good deal.

 

[Benjamin1031]

::016::

With fork bottom clamped in a vice I used ratchet straps to compress it, and even with the special tool from Traxxion it still took 2 people. I would love to see a video showing how u did it all by yourself with just a rope.

I wish that I had filmed it for proof if nothing else... I have a buddy with an s10 maybe he needs his done. If so I'll take a vid.

 

[RCinNC]

Or you could make a totally safe spring compressor out of 25 bucks worth of aluminum and a couple wood clamps, that won't cause any of those heart stopping "Holy Crap!!!" moments.....

 

[Tenman]

I don't think many riders are up to making that cool spring compressor.

 

[Pterodactyl]

I was truely inspired by the OPs Rube Goldberg efforts. So inspired I took my front forks to our local suspension shop to have the left lower fork replaced (deer strike) and both oil seals replaced. I supplied all the parts except the oil and it cost $120. I do 95% of the work on my bikes, but this was just too easy. ::025::

 

[RCinNC]

I don't think many riders are up to making that cool spring compressor.

Anyone who took woodshop in school, or has even a basic familiarity with hand tools, could make this; it's just an open ended box made from aluminum. There are a bunch of photos of it at this link ( http://www.yamahasupertenere.com/index.php?action=media;sa=album;in=95 ) to show how simple it is to make and use.

 

[greg the pole]

Is a fork spring compressor recommended because the springs on this bike are really heavy duty ? I rebuild the forks on my MX bikes all the time , no special tools.

Nope. The spacer must be compressed out of the way in order to break the nut/top cap apart.

 

[snakebitten]

Anyone who took woodshop in school, or has even a basic familiarity with hand tools, could make this; it's just an open ended box made from aluminum. There are a bunch of photos of it at this link ( http://www.yamahasupertenere.com/index.php?action=media;sa=album;in=95 ) to show how simple it is to make and use.

I am old and no longer in a hurry. So maybe someday I will indeed be inspired to use your efforts to fashion up my own spring compressor. So thanks!

However, I know me. It isn't because I am in a hurry that I would "outsource" the work. It's more that I am spoiled rotten and could be riding another bike while some friendly tech is earning his wages addressing this one. Everybody needs Kroger money. I'll probably just oblige.

 

[RCinNC]

I hear ya, Snakebitten, and I can appreciate just taking a bike to someone else to fix, or buying a particular tool. I still take mine in if it's something I just don't want to do myself, either from lack of time or lack of desire. Primarily, I just like to build things and design things, whether its a custom made holster for a handgun or a tool to work on the bike or a luggage attachment system. I just wanted to dispel the idea that building the tool was complicated, since it isn't.

 

[snakebitten]

Yep, I'm betting you enjoy designing and building "the tool", as much or more than accomplishing the task the tool was needed for?

Again, I see the allure.