Fork Rebuild 1980G

[DGXSER]

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

Hey Phil,

Maybe its just me, but I tend not to blow on long round tubular things. Not that there is anything WRONG with that of course. Its just not something I do.

Oh..and what in the tarnation is a didgeridoo? I am apparently getting a global slang edumication today.

[MaximPhil]

Hey Phil,

Maybe its just me, but I tend not to blow on long round tubular things. Not that there is anything WRONG with that of course. Its just not something I do.

Oh..and what in the tarnation is a didgeridoo? I am apparently getting a global slang edumication today.

An Australian wind instrument. I'll look for a picture.
Here you go http://www.didjshop.com/ everything you need to know. I bet your make up would be black grease instead of the more usual white clay
Phil

[MPittma100]

Easy Enough

I made 2 tools: the 1/2 inch bolt (3/4 inch head) with 2 nuts and a length of 1.5 inch PVC pipe for a seal driver.

Got both forks apart, cleaned, and back together with no problems. The tips and home made tools worked as well as any professional ones. I am obliged to all of you who helped. There was quite a bit of sludge in the bottom of each fork and this bike only has 16K miles on it. Must be the 33 year sludge. The seals were apparently original as they had the fork manufacturer's name on them. Only one was leaking, but 2 new seals will go in.

I have noticed that when you put the fork caps back on (especially when the forks are still attached to the bike) that it is rather difficult to get them started back into the forks. Does anyone have a special trick for that or is it just me?

Mike

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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[DGXSER]

If it has the air valve caps, I use a piece of 1X4 oak about 4" tall with a slot cut out that fits over the air valve cap, sits on the straights. I use that to push down and turn at the same time. Push carefully as these are fine threads. I actually pull the spring out, then sit the cap on the fork tube and find the point where the threads start, and mark that on both pieces. That way I know where to start it with the spring in place.

[MarkD]

After my fork seal job, I had the forks installed on the bike. Would have been easier to put caps on when they were out. Anyhoo, I removed the handlebars, and simply used a socket and ratchet and CAREFULLY pushed and turned to screw cap in.

[bikerphil]

Yep, the 78-79 Standard forks without air, a 22MM socket and a ratchet may be used to install the caps, other models with air, a simple tool like Don mentioned can be fabricated..... ↓

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[MPittma100]

Forks Finished

I did get the forks finished. Thanks for all of your help. Took a while to get past installing the seals due to the fact that there are a lot of opinions from seal distributors as to what is the correct seal for these forks. It took a third set of seals to be the correct ones and that is two more attempts than I am usually happy with.

A set of Pyramid seals came with the bike from the PO. They were close, but no cigar. Ordered another set on Ebay called "leak proof" seals and they were once again "close". Finally a set from Bikemaster fit properly and are currently installed. I have another set from K&L. They look closer to the right ones, but are not exactly like OEM.

As a back-up, I have obtained 2 sets of OEM Yamaha seals that are the KYB brand which I feel like I can trust without a problem.

Another not so good word about K&N: I bought 2 K&N petcock rebuild kits on Ebay. One of the kits did not have the petcock to tank rubber gasket. I contacted the dealer "filterking" twice regarding the missing item. To date I have had no response. It has been 3 weeks.

As a result, I will not buy from "filterking" again and I recommend that any of you do the same. There are other vendors that I will find to deal with.

Mike

[jetmechmarty]

Another not so good word about K&N: I bought 2 K&N petcock rebuild kits on Ebay. One of the kits did not have the petcock to tank rubber gasket. I contacted the dealer "filterking" twice regarding the missing item. To date I have had no response. It has been 3 weeks.

As a result, I will not buy from "filterking" again and I recommend that any of you do the same. There are other vendors that I will find to deal with.

Mike

Do you mean "K&L"? Many of us have had very good luck with GEORGEFIX'S MOTORCYCLE PARTS for these items. That's where I got mine.

[bikerphil]

Just for future reference...

Standard Fork Seal - 37X49X8
Special Fork Seal - 37X48X10.5

[MarkD]

As I posted earlier, just replaced my '79F fork seals with:

http://www.ebay.com/itm/Bike-Master-...L:COSI:US:1123

(tried to copy hotlink to item, , I guess copy the address in your browser)

item# 350817025156
on ebay
These babies were perfect. I used a roll of electrical tape to put on the seal, and popped them in by hitting the roll of tape with a rubber mallet. The roll of tape was the same size as the opening on top of the fork lower.

[MPittma100]

Forrk Seals

Do you mean "K&L"? Many of us have had very good luck with GEORGEFIX'S MOTORCYCLE PARTS for these items. That's where I got mine.

Hi Marty,

Yes, I did mean K&L. I will use George Fix in the future. I suspect that it was not filterking's error that the part was missing, but I certainly hold it against them that they chose to do nothing about it.

Mike

[b.walker5]

Oh..and what in the tarnation is a didgeridoo? I am apparently getting a global slang edumication today.

You need to get out more Don.

This is a didgeridoo.



Naturally hollowed out by termites, painted by bored abo's, and played by street buskers looking to make a few quid... , or sold to unsuspected tourists for far too much.

Traditionally, as Maximphil says, theyre a musical instrument that takes a skill called circular breathing to blow.

Theyre of no use whatsoever for dismantling forks.....

[MPittma100]

Did What?

You need to get out more Don.

This is a didgeridoo.



Naturally hollowed out by termites, painted by bored abo's, and played by street buskers looking to make a few quid... , or sold to unsuspected tourists for far too much.

Traditionally, as Maximphil says, theyre a musical instrument that takes a skill called circular breathing to blow.

Theyre of no use whatsoever for dismantling forks.....

Now that is something that we don't see everyday.