Fork rebuild / overhaul help please

SvenDGAF · Mar 14, 2009

Ok, I know there is vast amounts of info on forks on here - and I'm a little overwhelmed with info. I would appreciate it if someone would read my specific case and comment on what I need etc.

Firstly - I am very poor and need to keep this cheap! I have never removed the forks or replaced the oil or anything an my vmax. I have an '85 (owned for 2 years) which only has around 38,000 km on the clock. The dust seal started weeping oil just before Oct last year - and although it has been ridden on and off over the winter, i haven't got around to this job (i know i should have).

The front end seems weak when hard braking / accelerating.

I have a detailed "Haynes" service manual and I have been scanning through it as well as reading threads on here.

Can anyone tell me what I will need to get and expect to find on this rebuild? I know I need oil seals. Should I replace the dust seals too? I want to stiffen up the front end a bit... so 20wt oil? and will the springs still be good? what's my cheapest option to upgrade the springs? or maybe replace with new stock ones and go ahead with the heavier oil? what air pressure afterwards? and any specialist tools techniques I should use?

Many thanks in advance to all. This forum has helped me a lot over the course of owning the worlds most awesome bike

unk:

one2dmax · Mar 14, 2009

Progressive springs (I think I sell them for $100 or less including shipping) would be a good start. I normally get in the habit of replacing the dust seals but it's not always needed. They do help keep crap from getting past it and into the oil seal. Look at yours well and see if they are heavily cracked.

Sean

broook · Mar 14, 2009

Progressive springs or equiv. Anything but stock. Did mine last year.
You can then forget about air pressure.
DO NOT buy aftermarket seals. I tried two sets and thought my forks were gone but somebody on this forum sugested the Yamaha seals. They cost a bit more but are worth it.
I didn`t change the dust seals but that is up to you.
If one side is not leaking, leave it alone if money is a problem. [It is with me]:rofl_200:

SvenDGAF · Mar 14, 2009

broook said:
If one side is not leaking, leave it alone

I think if i ONLY do one side inc. progressive springs, i'm likley to go round in circles and/or head straight into a tree! :biglaugh:

SvenDGAF · Mar 14, 2009

one2dmax said:
Progressive springs (I think I sell them for $100 or less including shipping) would be a good start. I normally get in the habit of replacing the dust seals but it's not always needed. They do help keep crap from getting past it and into the oil seal. Look at yours well and see if they are heavily cracked.

Sean

The dust seals look fine to me.....

So how much would a set of prog springs be (inc shipping) to UK?

I'm just a poor apprentice electrician :confused2:

:biglaugh:

broook · Mar 14, 2009

SvenDGAF said:
I think if i ONLY do one side inc. progressive springs, i'm likley to go round in circles and/or head straight into a tree! :biglaugh:

My fault for not explaining properly, sorry.
You can change the springs and oil on one side without removeing the seal if you wish.:bang head:

82ndCowboy · Mar 14, 2009

I would go with replacing the oil seals and dust caps and the fork oil, at the very least. That is going to be your cheapest option. Do both forks, the other one will likely start leaking afterward. Not to mention it will be weaker than the new one.
Dust seals are important, they keep the dirt and grime from getting to your oil seals. And the money you spend on them is far more advantageous than shortening the life of the new oil seal.
Then if you can afford it upgrade to the progressive springs. They are a big improvement over the stock air assisted springs.

mabdcmb@yahoo.com · Mar 14, 2009

Python Motorsports sells Progressive springs pretty cheap. 65.99 USD for stock height. If you want to lower the front end an inch or two it'll cost you and extra 20-25 USD. Not sure what shipping across the pond would be though.

mivmx · Mar 14, 2009

I am lowering mine with Progressive springs and rear shocks. Do I understand correctly that air press will NOT be needed when finished? Thanks.

veebooster · Mar 14, 2009

Get rid of the stock springs! You won't regret the expense. Best bang for the buck Vmax mod there is!!

Dale #2592

one2dmax · Mar 14, 2009

Feel free to email me direct and i can check the current pricing. get me the bike info and where shipped to.

Sean

SvenDGAF · Apr 17, 2009

Ok, a brief update.....

I went for Hagon progressive springs and Silkolene sae15 fork oil....

all ready to start the job....

and now i'm stumped again, as the brake caliper bolts on the left side are both seized up ......

oh joy

dannymax · Apr 17, 2009

SvenDGAF said:
Ok, a brief update.....

I went for Hagon progressive springs and Silkolene sae15 fork oil....

all ready to start the job....

and now i'm stumped again, as the brake caliper bolts on the left side are both seized up ......

oh joy

That's a bummer!!

Did you try spraying on some good penetrating oil, letting them sit overnight, then give the wrench a good sharp whack with a rubber mallett?

I've found that steady and increasing pressure on frozen bolts will result in rounded heads or broken parts more often than a good sharp rap.

Good luck!

one2dmax · Apr 17, 2009

Actually, you can get them to break loose many times by actually tightening them a little first.

Sean

4gasem · Apr 17, 2009

I put a little anti-seize on mine and torque them to specs.

Make sure you do the same with all the bolts.

Chris

SvenDGAF · Apr 17, 2009

4gasem said:
I put a little anti-seize on mine and torque them to specs.

Make sure you do the same with all the bolts.

Chris

Yeah man, I always paste my bolts with copper grease before torq-ing them up. But i haven't removed these bolts yet, and they locked up solid. I might go to the garage and get them to undo them with an impact wrench:bang head:

naughtyG · Apr 17, 2009

You mean you don't have an impact driver? Do yourself a favour, for the money you're gonna give to the garage, you can get yourself a decent impact driver with all the screwdriver and allen bits. Well worth it on the Vmax - you will use it again and again. Just don't go to Halfords or B&Q - they sell ***** overpriced tools. Just go to your nearest trusted motor factors and you won't regret spending the 20 or 30 quid...

gamorg02 · Apr 17, 2009

naughtyG said:
You mean you don't have an impact driver? Do yourself a favour, for the money you're gonna give to the garage, you can get yourself a decent impact driver with all the screwdriver and allen bits. Well worth it on the Vmax - you will use it again and again. Just don't go to Halfords or B&Q - they sell ***** overpriced tools. Just go to your nearest trusted motor factors and you won't regret spending the 20 or 30 quid...

i think he meant he was going to HIS garage to use his impact wrench

naughtyG · Apr 17, 2009

he said 'go to the garage and get THEM to...' :confused2:

SvenDGAF · Apr 18, 2009

Is an impact driver thing, that electric / air driven power tool that undoes bolts?

If so, that's what i meant. I dont have one, only hand tools

Fork rebuild / overhaul help please

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