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Post by gazzatt2 on Dec 9, 2019 22:13:41 GMT 1
I have a set of the above fitted to my A/C 400 I need to strip them down
is there an idiots guide anywhere
any special tools needed
tia
Gazza
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Post by JonW on Dec 11, 2019 12:47:03 GMT 1
nope, its a really easy fork to work on.
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Post by Deleted on Dec 11, 2019 17:29:46 GMT 1
Yep as Jon says real easy
The only specialist tools required I think are a rattle gun, battery will do and a longish in hex allen key that fits the rattle gun for the cap screw in the bottom of the fork
First let any air out of the forks, you will regret it if you don't, remove the top valves be careful they could be under pressure from the fork spring or any air you neglected to remove at the start
drain the oil then pump the stanchion up and down a couple of times to drop any remaining oil
Put an absorbent rag under the end of the fork to catch oil, undo the bottom cap screw using the rattle gun, or as i have done before jammed a broomstick on top of the damper rod to let you remove the cap screw, it's harder work that way, rattle gun is better, it spins faster than you can
Lift off the dust seal a small flat blade screwdriver will do this, remove circlip
Hold the bottom of the fork in a soft jawed vice or similar and pull on the stanchion by using it like a slide hammer to remove the top seal, it may take a few decent blows to pop the seal, but it will come out relatively easily after 4 or 5 efforts
Keep that seal you'll need it later
Remove spring, damper rod etc change the top and bottom slides, clean out the fork bottom and stanchion, a good quality brake clean will do this or use petrol, keep the petrol oil mix it comes in useful for keeping parts rust free
Mind you if the oil was anything like mine, you may want to leave that idea well alone, mine was dark grey nearly black and stunk, we think it was a graphite type oil in there
Put back all the internal hardware back the reverse way it came out damper rod, damper spring, spacer etc
Put on new seal and slide down the stanchion,spring side down, slide the old seal down on top of the new one and using a soft hammer tap around the top of the old seal to set the new one home, put the clip back in to its slot and tap the top dust seal in over the top
Fill with the required level of new oil, replace end caps, you may need to press down hard on the end caps if you've got a bit of extra length on the spring, jobs done in 30 minutes
If I've forgotten any thing someone will be along to correct me, however thats the basics
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Post by JonW on Dec 11, 2019 22:04:15 GMT 1
Thats a good write up Howard, one thing I do with all forks like this is drain the oil and then undo the bottom bolt with the rattle gun at that point as its held by the spring with the caps still on.
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Post by cb250g5 on Dec 11, 2019 23:29:39 GMT 1
You really need a 3rd hand to get the pesky circlip out whilst pressing the top cap down. Real fiddly job, especially if water has got in & its a bit rusty in there.
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Post by JonW on Dec 12, 2019 12:32:54 GMT 1
In my 251LC thread i show a trick about getting the top cap down and clip out on your own...
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Post by dougw on Dec 12, 2019 13:14:39 GMT 1
Good write up hblair,
Hot air gun around top of stanchion before
"Hold the bottom of the fork in a soft jawed vice or similar and pull on the stanchion by using it like a slide hammer to remove the top seal, it may take a few decent blows to pop the seal, but it will come out relatively easily after 4 or 5 efforts"
Makes it even easier.
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Post by Deleted on Dec 12, 2019 16:48:01 GMT 1
Nice tip Doug, never knew that one
Makes a lot of sense though
Howard
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Post by gazzatt2 on Dec 26, 2019 15:53:42 GMT 1
stripped them down
one came apart by undoing the bolt before removing top valve
removed the other with the broom handle to hold it as had took top valve off
how do you tighten the bolt on assembly
the other thing is I have is that the springs are 420 mm in length and a massive spacer fitted
the springs don't look cut down
is this a known mod ?
I am having the stanchions cut down by 35mm
to I use the standard reading for oil height less 35mm ?
Gazza
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Post by midlifecrisisrd on Dec 26, 2019 17:15:26 GMT 1
The spacer is standard
Yes drop the airgap 35mm and cut the spacer down
To tighten the bottom bolt I always do it first so I can use the brush handle or spike method if required
Nine times out of ten they will tighten no problem
Steve
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Post by gazzatt2 on Dec 28, 2019 20:39:58 GMT 1
thank you
just need to find what the standard air gap is cannot find it in the manual I downloaded
tia
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