Fork Rebuild 1980G

[MPittma100]

I'm trying to get the front fork apart to replace the seal. Allen bolt in lower end turns but will not come out. What am I doing wrong?

Thanks, Mike

[natemoen]

Shove a wooden broom handle or dowel rod down there to hold it still.

[DGXSER]

BikerPhil has a tool, basically all thread with IIRC 19 mm nuts on each end that fits in there to stop it turning.

[MarkD]

Read this--- Been there done that, just a week ago.

http://www.xs11.com/forum/showthread...ght=fork+seals

[bikerphil]

Find a bolt with a 19MM head (3/4" should also work) and tighten two nuts together on the end. With the fork laying on the bench, put the double nut end in a deepwell socket with a long extension, slide it into the fork tube and the head of the bolt will fit into the damper rod as shown in the pic below. Now you can hold it from spinning while you undo the allen bolt on the bottom of the leg.

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[jetmechmarty]

This is the tool that goes down into the fork to hold the damper rod.

Down in the fork assembly the top of the damper rod looks like a socket.


You can make a tool.


Some time ago, I was having this same issue with my Special and asked the same question. (The Special damper rod has no teeth in it to grip.) Bikerphil said to cram a broomstick against it and that will hold it. He was right.

[DGXSER]

Maybe I have been lucky with the Special forks I have rebuilt. I always break the allen bolt loose, then when it starts to turn the damper rod, I grab the upper tube with my thumb and for finger, and the lower slider with my other three fingers, then spread my fingers to create a friction of the slider pulling on the damper rod that holds it from turning while I remove the bolt. I do have to get a new grip every so often as the bolt comes out. Ehh...It works for me anyway.

[MarkD]

I made the same exact tool Jet...marty made. Easy peasy.

[Schming]

Hi Mike, the following pic is of my '80 G's forks broken down for rebuild and on the top the three tools I used for disassembly.

The only part missing is the fork spring itself, but I'd imagine you would know where they go.




Just thought it might help upon reassembly if there was any question on which parts go where.

Also a good idea to reinstall the two Allen bolts with a little blue locktite and just a spot of gasket sealer under the washer just 'cause.

[jetmechmarty]

I made the same exact tool Jet...marty made. Easy peasy.

I can't take the credit. I found those images using Google.

[rdmcguy]

fork springs

Thought I might add that the small coil portion of the fork spring
belongs on the bottom (lower)
Joe

[MPittma100]

1980G Fork Repair

Thank you all. I was stumped for sure. So I stopped and asked and wow!. Great, quick information. And I thank all of you. Made the tool and will proceed to disassemble and rebuild.

Mike

[CaptonZap]

Hi Mike, the following pic is of my '80 G's forks broken down for rebuild and on the top the three tools I used for disassembly.

Also a good idea to reinstall the two Allen bolts with a little blue locktite and just a spot of gasket sealer under the washer just 'cause.

LOL.
If you do use Locktite, you will need the nuts-on a-stick to get them apart next time, a broom handle won't get it.

CZ

[Schming]

LOL.
If you do use Locktite, you will need the nuts-on a-stick to get them apart next time, a broom handle won't get it.

CZ

Mine were put on from the factory with locktite so I figured there was a reason.

And yes they were a bitch to break loose even with the tool I fabbed.
What also isn't in my pic is the 18" cheater pipe I used with the ratchet while standing on the wrench.

[MaximPhil]

Maybe I have been lucky with the Special forks I have rebuilt. I always break the allen bolt loose, then when it starts to turn the damper rod, I grab the upper tube with my thumb and for finger, and the lower slider with my other three fingers, then spread my fingers to create a friction of the slider pulling on the damper rod that holds it from turning while I remove the bolt. I do have to get a new grip every so often as the bolt comes out. Ehh...It works for me anyway.

Hi Don,
If you blow in the end while holding your fingers like that does it sound like a didgeridoo
Phil