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Re: How to take off front forks to rebuild . any special...
Relatively straight forward. Pull the brake caliper and tire off, turn signals if fork mounted, and loosen the clamps on the triple trees. Twist them a little for easier removal
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hi
im sure it is what is called a c spanner
they use the same spanner to adjust the fork bearings on push bikes also on the crank
they also use that tool to adjust suspension springs
here is a link to some bsa workshop manuals for you to look through and see what the tool looks like
Free BSA Motorcycle Service Manuals for download
A little bit of Trans fluid and the seals, flushing the forks and some elbow grease and a shop manual is strongly advised. This is not a simple job but doable. I made a special tool out of PVC pipe for this task also. You really need a shop manual.
There are severall answers to this question (with videos) if you use a search engine for "rebuild marzocchi xc fork". You can get creative with the search terms.
As far as parts availability is concerned, scour the web (search engines again) or eBay.
Maybe hit the marzocchi site, register and ask them or search for documentation.
Hello, It is not out of the ordinary to have the forks leaking on a 1982 bike. The forks should be rebuilt with new seals and bushings. It is about a four hour job to do this. One thing to pay close attention to is the inner or chrome portion of the fork. If rust pitts have developed on the inner tube the rebuild will not last. Each time the fork goes up and down over the rust pitts, it tears the seal.
There are special tools required to rebuild the forks so they should be rebuilt by a qualified technician.
You should be able to do this job provided you have a way to get the bike off the ground. Lifting the bike off the ground enables the forks to extend all the way. This is necessary because the stock spring will be longer and stiffer requiring a bit of compression when reassembling the fork. You may need a tool or a helper to compress the spring while you thread the fork tube cap back into the top tube. There is a special tool that is made to assist with this. Whether or not you'll need this tool, I'm afraid I can't answer that with guaranteed accuracy. I know that I've serviced many front fork assemblies without any special tools. This information applies to the standard Hydro-Shock front end only, not the Springer front end.
FORK OIL
• Place the front fork vertically without spring.
• Compress it fully.
• Pour specified front fork oil up to the top level of the outer
tube.
Capacity (each leg): 490 ml (16.6/17.3 US/lmp oz)
99000-99044-L01: SUZUKI FORK OIL L01
or an equivalent fork oil
• Move the inner rod slowly with the special tool ten times and
more until no more bubbles come out from the oil.
09940-52841: Inner rod holder
NOTE:
Refill front fork oil up to the top of the outer tube so that bubbles
are visible while bleeding air.
• Refill specified front fork oil up to the top level of the outer
tube again. Move the outer tube up and down several strokes
until no more bubbles come out from the oil.
• Keep the front fork vertically and wait 5 – 6 minutes.
NOTE:
* Always keep oil level over the cartridge top end, or air may
enter the cartridge during this procedure.
* Take extreme care so as to pump out air completely.
• Hold the front fork vertically and adjust fork oil level with the
special tool.
NOTE:
When adjusting the fork oil level, compress the outer tube fully
without the fork spring.
Fork oil level: 153 mm (6.02 in)
09943-74111: Front fork oil level gauge
This might be the info you need:http://srsuntour-files.dbap.de/_public/tuningbase/downloadarea/explosions/Fork/Generic_hydraulic_air-SF-instruction_sheet_E_2007.pdf If this doesn't help, I'd recommend taking your bike to a good repair shop to have the front fork serviced. Your problem could be a number of things such as adjustment, familiarity with the settings or failure of parts in the shock. It is easier for a bike tech to look at it in person and diagnose your problem. It might be a simple adjustment and having your shock pumped up or it may need a rebuild which requires special tools and access to parts.
The best way, is with the manual that comes with the bike new, if you don't have it, find or borrow one (Same model and year) because it has all of the steps and fluid capacities in it. There is no way to "talk" you through it.
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