How To Rebuild Dirt Bike Forks

Video How to Rebuild a Ground Bike Fork In this video, we show you how to rebuild a dirt bike fork seal and bushing and change the suspension fluid.

How to rebuild mud bike forks

For this demonstration, we’re using a KYB 48 ml pneumatic fork (AOS) from the 2009 Honda CRF450R. The lower fork foot moves causing soot; dirt or debris breaks the seal; or a rock chip or nick in the lower fork tube slips through and tears the seal.

Tools you need

• Owner’s manual or other instructions for installing fork seals
• Suspension fluid (at least two liters per fork)
• Fork washers and bushings
• Properly sized seal driver
• Bullets to help install the seals
• Sealed driver
• Fork cap hex wrench and fork cap wrench
• Power wrench
• Soft hammer
• Screwdrivers
• Option
• nitrile gloves
• 17 mm and 19 mm . socket and ratchet
• Wrench 14 mm
• Brake contact or cleaner
• Drain pan
• Cylindrical cylinder

Test clicker compress and resend

First, use a standard screwdriver to determine the setting of the compressor and turn it back on. Starting with the compression, turn the screw clockwise and count the number of clicks until it snaps into place. Write down the number. Then, open the compression valve all the way until it stops.

Discharge liquid suspension

Next, clamp the fork assembly to a clamp using a pair of soft jaws and loosen the cartridge cover nut. Remove the fork body and tilt it upside down to drain the suspension liquid into the drain pan. Smash the fork body into the cover and loosen the bounce adjustment nut. Once the threads make contact and it has stopped moving, it’s time to compress the spring. Use a 14 mm wrench to secure the lock nut and the bottom of the fork lug. Remove the trigger nut. It’s important to pull the bounce bar out so it doesn’t drop and get damaged. Compress the spring and remove the wrench. Now, open the lid and slide the fork body down. You can now remove the ink cartridge. There should be a spring with it. Put everything aside for now.Next, remove the dust seal. Use a small standard screwdriver and hammer to pop it out. Remove the small retainer with a fork.

Removal of seals and bushings

Read more: Fallout new vegas how to get a companion Now let’s separate the lower tube from the top tube. Oil seals, dust seals, retaining washers and bushings will be left on the lower pipe. To remove the inner bushing, use a flat-head screwdriver to open the slot and slide the bushing over the edge. Slide the bushing, retainer, oil clip, and other dust seal off the bushing and place everything on the table in the order removed. Remove the spring from the fork, washer, and spring seat. Remove the O-ring, rebound regulator, and brass washers. Clean everything with contact cleaner or in a component washer. Dry all parts with compressed air when you are done cleaning or let them drip. Next, remove the compression assembly and piston from the cartridge using the hex wrench on the fork cover. Remove the compression valve and set it aside in a clean container. Drain the oil from the toner cartridge. While it is draining, check the compressor assembly and free piston for damage. Clean with an O-ring safe Brake & Parts Cleaner or a parts washer. Dry with compressed air.

Fill the cartridge with suspension liquid

Clamp the cartridge in a sticker. With the compression assembly in a clean container, add suspension liquid to soak the assembly and help remove air bubbles. Before filling the cartridge with liquid, seal the transfer ports closed with masking tape. Pour in the suspension slowly to reduce air bubbles. Move the damper bar slowly to distribute the liquid throughout the cartridge and dislodge air bubbles. From above the liquid down just below the fibers.

Compression assembly settings

Extend the damper as far as it will move. Remove its suspension liquid cartridge assembly and insert it into the cartridge. Rotate the assembly and install at an angle to remove as many air bubbles as possible. It will eventually float in the liquid vertically up and down. Let it settle into the cartridge until it stops. Next, move the lower damper up while applying light pressure to the assembly.

Bleed Air from the cartridge

Start by gently holding the compression assembly and pushing the damper bar up. The compression assembly will increase with the damping rod. Eventually, it will stop. At that point, push about 15 to 20 mm further and then fully extend the damper rod, which will pull the assembly into the cartridge until the threads touch each other. Fasten the assembly to the cartridge with the fork cap hex wrench and torque wrench. Next, remove the cartridge from the cover and remove the tape on the transfer ports. While holding the fork assembly on the drain pan, push the damper to remove excess liquid from the ports. Extract the damper rod and repeat until the liquid is removed.

Check Shock Absorber Bar Action

Clamp the cartridge back in the lens to make sure it’s working correctly. Push the damper bar until it stops. Then let it go. It will recover smoothly with no liquid leakage at the sealing rings.

Install new fork seal

Clip the lower fork tube to the vise. Check its surface for cracks or deep scratches. Use a 400 grit or higher sandpaper to sand anything you can feel with your fingernails. Always sand perpendicular to the fork tube.Read more: How to pour MAC makeup | First Q&A Next, install the new fork washers and bushings. Place the bullet over the tip of the fork tube. While wearing gloves, dip your finger in the clean suspension and lubricate the fork tube. Next, install the clamp that holds the oil seal, then the oil seal. It helps to lubricate the inside of the seal. Next, install the new gasket and bushing, now we are ready to install the outer spring tube. Lubricate the inside for easy installation and slide it into the fork tube. Use a properly sized seal driver to mount the seal. Rotate the outer tube while driving the seal to ensure it lies evenly. To see when it’s in place, use a flashlight to check if the seal is under the clamp. Now let’s install the clip. It will emit an audible sound when lowered into position. Finally, slide the dust seal in.

Spring Settings

Now, it’s time to install the cartridge and spring into the fork. First, install the O-ring and spring seat into the cartridge. Be sure to check the O-ring and bushing condition prior to installation. Then replace the spring seat.

Install the return valve

Next, cut the bottom of the jam nut on the damper bar to make room for the return valve. To assemble the restorer assembly, start by mounting the washer washer, paying attention to inspect the O-rings. Before mounting to the fork body, install the spring washers. Next, install the spring. With the fork tube mounted in the viscous tube, install the cartridge assembly, guiding it into the center of the spring until it reaches the bottom. Use the rebound rod to guide the assembly as you push it into place. Finally, install the bounce bar. Fasten the assembly to the fork foot according to the correct torque rating.

Add suspension liquid

Each suspension company will send a suspension sheet specifying the exact volume of liquid to add to the fork. When pouring the suspension liquid, tilt the fork and make sure the top tube is facing down so you can pour around the compression tube. Once you’ve added the liquid, slide the lower fork tube up and fasten the top cap. Torque according to proper specifications.

Reset the compression clicker and turn it back on

The final step is to set up the compression and recovery clicker to factory settings. Place the jacks using a screwdriver, then duplicate them with the same number of clicks recorded earlier.

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