It's my turn

Questions and comments about converting to beefier forks..
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muddertrucker
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It's my turn

Post by muddertrucker »

I'm almost done putting this thing together, I just need to go get some oil and my axle is in the mail (I hope it fits)

So far the total cost is:

97 KX 250 forks 1$

[img][img]http://i347.photobucket.com/albums/p449 ... ruk031.jpg[/img][/img]

97 KX 250 Triple clamps 2$
[img][img]http://i347.photobucket.com/albums/p449 ... ruk033.jpg[/img][/img]
[img][img]http://i347.photobucket.com/albums/p449 ... ruk034.jpg[/img][/img]

02 KX 250 front wheel 146$ shipped to my door

[img][img]http://i347.photobucket.com/albums/p449 ... ruk032.jpg[/img][/img]

96 Kx 250 front axel 20$ shipped to my door. (no pics yet)

Rebuild kit, fork protectors and seal savers 155$ cdn + 1 nasty look on my wifes face.

[img][img]http://i347.photobucket.com/albums/p449 ... ruk030.jpg[/img][/img]

It adds up to more or less 350$ (so far)
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SVandal
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Post by SVandal »

Looks like a good start. Also, I think I know which look your wife gave you. Probably the same one mine did when I started my hybrid :grin:.
mudsplasher
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Post by mudsplasher »

I also know that look. That's why I hide my bank statement from her, and I don't see hers either.
SVandal
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Post by SVandal »

>|<>QBB<
mudsplasher wrote:I also know that look. That's why I hide my bank statement from her, and I don't see hers either.
We do a shared account, I just have to let her know ahead of time when I am going to be ordering which is generally followed by a "do you really need that?" and then the look. But it works, my bike is almost done and she is looking forward to putting more in to savings rather than into the bike.
mudsplasher
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Post by mudsplasher »

This is the second marriage for both of us, and we decided before getting married that we would have separate accounts and pay our own bills due to past experience. Bad experience.
SVandal
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Post by SVandal »

>|<>QBB<
mudsplasher wrote:This is the second marriage for both of us, and we decided before getting married that we would have separate accounts and pay our own bills due to past experience. Bad experience.
Whatever it takes to make it work. Money seems to be the root of most marriage problems so as long as the system you and your wife use works for both of you then it looks like you are on the right track. Congrats on finding a wife that tolerates the "need" to tinker with bikes :grin:.
muddertrucker
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Post by muddertrucker »

It's all done now. I had a couple issues while pressing the stem. It seems I cant read, I tried pushing it out through the top. One bent to crap KDX lower clamp and some broken threads on the stem later, I guess I learnt my lesson I was tring to do this to fast. I also realized that I had not measured the height of my bike prior to disassembly, so I just did what I read on here and set the forks 1/2 inch out the top of the clamps.

Other than that every thing went well. I didn't have the right thickness of shim stock so i put two layer. The were only clearence issues on one side so I drilled one of the KX lower clamp stops and put a small bolt through.

[img][img]http://i347.photobucket.com/albums/p449 ... der008.jpg[/img][/img]

I also made some handlebar spacers because once the forks were raised a 1/2 inch the was no more room to adjust the clickers.

[img][img]http://i347.photobucket.com/albums/p449 ... der007.jpg[/img][/img]

I made a braket to hold the brakeline on the fork protector but because I don't have any guides it rubs up against my seal savers and will tear them up in the long run. I covered the back in silicone but already started to peel off.

[img][img]http://i347.photobucket.com/albums/p449 ... der002.jpg[/img][/img]

I took it to the end of my street and about the first 100ft of trail wich is pretty rocky and noticed a significant difference over the stock forks but have a feeling the still lots of tweaking to be done

Here's the end result.

[img][img]http://i347.photobucket.com/albums/p449 ... der013.jpg[/img][/img]
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muddertrucker
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Post by muddertrucker »

Well I cured my issue with the fork guards by cutting a piece of plastic and held it in place where the guard rubs using zap straps. Looks like crap but so far so good.

I took the bike for it's real (but short) test ride today, first I went to a small track wich was made just so people could practice jumping. The stock forks used to bottom out but the USD's handle jumps (I only do small ones) very well, after all thats what they're made for. I then went to my favorite spot...the hydro lines. This trail is mostly one big rock with stair looking climbs.

Do the USD's make faster....probably not but they deffinetly make it seem like I'm not fighting to make the bike go where I want to anymore.

Through out the ride I kept hearing clunk noise coming from somewhere in the front of the bike mostly accompanying the bigger hits (jumps and rocks). When I got home I took a good look at it and found out it was only the top steering stem bearing.
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canyncarvr
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Post by canyncarvr »

So...you're happy with the result, I take it?

Re: 'it was only the top steering stem bearing.'

Is that part of the trying to do it too fast, too? There is a specific method to assembling anything with tapered roller bearings.

Good thing you caught that right off. A too-loose stem makes for a hard life (and a short one) for the lower bearing.

Sounds like an economical set-up, too!

Good job!

(Well..as long as nothing else ends up knocking around.......) :wink:

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muddertrucker
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Post by muddertrucker »

>|<>QBB<
canyncarvr wrote:So...you're happy with the result, I take it?

Re: 'it was only the top steering stem bearing.'

Is that part of the trying to do it too fast, too? There is a specific method to assembling anything with tapered roller bearings.

Good thing you caught that right off. A too-loose stem makes for a hard life (and a short one) for the lower bearing.

Sounds like an economical set-up, too!

Good job!

(Well..as long as nothing else ends up knocking around.......) :wink:
Well the top bearing is only a drop in and tighten the nut sort a thing so it's kinda hard to go too fast. I was trying to get the whole set up done for a group ride on saturday. Last monday was a holiday giving me only a 4 day week, wich is one day less than what I needed to get it done on time giver my litle screw ups. Once I decided not to go to the ride on saturday I slowed my pace down and made sure the forks were put together right and that the whole assembly was done properly. Besides 100km with a setup that hasn't been tested is not a good idea if you ask me.
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