KDXRIDER.NET

Hey all, new to the site here as I'm having trouble removing the fork tubes from my '01 220r. Can anyone give some directions/links/tips/list of required tools? One of the tubes is bent and needs to be fixed/replaced.

Thanks!

You can't remove the fork from the triple clamp or you can not separate the two tubes???

You may want to just buy a set of used forks off ebay.

if you do decide to buy a set let me know...i got some im willing to part with

Thanks for the note. Problem is that I can't separate the 2 tubes...I don't have an enclosed area to work on the bike, so I want to leave as much assembled for as long as possible (forks on bike, spring in forks) to avoid dirt contamination. Tried removing the hex nut at the bottom of the forks, but it is incredibly tight and I wanted to be sure of what I was doing prior to accidentally breaking something that wasn't supposed to be removed. I know the forks will need to be removed to set the oil level in the new/repaired tubes.

diymirage, how much do you want for them? Full forks, or just tubes?

Bendedrummrer:

Do you mean you can't remove the tubes from the triple clamps? If yes, you need to spread the gaps where the clamp bolts go through. I did it by removing the bolts and installing them from the threaded side. In the gap, I placed the 12" blade from a machinist's combination square. Then when you tighten the bolts they bear against the steel rule blade and act as jack screws, increasing the gap. For me, this worked like a charm and the tubes could just be pulled right out.

Bendedrummer wrote:
diymirage, how much do you want for them? Full forks, or just tubes?

good question on the price
a quick ebay search will put you at about 100 dollar shipped for the pair, so i can do 75 shipped?

now, on to the forks, they are complete with boots but the boots have seen better days
they came from a 96 i bought a while ago and they dont seem to be leaking or faulty...just old

they do have some scratches...normal wear and tear
the only real flaw i can see is the studs that hold the front axle on...they are all 4 missing and have been replaced with regular bolts

The base valve (14mm hex) has to come out, as well as the circlip on the seals.

diymirage, that would all be feasible for me (I have new boots), just not sure whether or not the small dent in mine will be fixable yet.

Jason, thanks for the info. How does one get to the circle clip?

Also, what manual do you guys recommend purchasing for repairs?

Thanks again

OEM only on the manual.

The circlip is on top of the dust seal, just use a little hook tool or screwdriver.

(take off fork boot)

Bendedrummer wrote:diymirage, that would all be feasible for me (I have new boots), just not sure whether or not the small dent in mine will be fixable yet.

no problem man, just let me know what you find

diymirage, it looks like it will not be worth it for me to try separating the fork tubes myself. Sorry for the delay in replying, it's been a very busy month.

Can I purchase the fork tubes from you still? And how would I go about paying you?

yup, i still have them, simplest way would be paypal: epj777_oost@yahoo.com
i will be out of town untill friday so i wouldnt be able to get them boxed up and send out untill tuesday (seeing as how monday is a holiday)

I also have a pair you can just have. They are beat and need serviced but visually ok and you could salvage parts from for later. I would still go with diys tho still. Just pay shipping is all I ask and can post some pics here of them. I wont need them anymore and will also be selling my rebuilt ones. Havent gotten the yz roller yet so I still need the ones on there.

diymirage, thanks, I'll send the Paypal on Tuesday then. Ship to: Ben Horarik 923 Dodge Street, Salida, CO 81201.

ICRage, thanks for the offer but I'm going to pass. I can still use my old forks for spare parts, and have most of what I need to rebuild diy's set. Mostly, I don't have space to store spare parts. Love your calvin and hobbes gif!

no worries Ive recieved so much help here I try to do the same. Thx Calvin and Hobbs is still great. Love the old strips.

got the payment today, i will ship the forks out tomorrow and get you a tracking number

Thanks!

wheni went to pack them up i noticed they werent in as a great a state as i remembered them to be
they should get there on saturday, have a good look at them (maybe give em good cleaning) and let me know if your satisfied with them
if not, we'll work something out

tracking (fed ex) is 795784900040

Ok, will do. I appreciate the heads up.

Hi Bendedrunner.
If things don't work out with those forks, I have a set of originals from an '03 220 that I would let go for cheap. Just need them out of shed/storage. Forks in great shape.
Ditton