Fork Disassembly - Twin shock models

[Rob Valdez 79 R65]

I got the caps and springs out by myself, but I needed help from my neighbor when it came time to loosen the 13mm way down in there, and the big a$$ allen screw that comes up from the bottom.

We had them freed rather quickly.

Then I went to take them apart.  The right leg came apart "normally", with the damper rod hanging out of the fork leg.

On the left leg, however, the top 13mm fastener came loose alright, but the allen screw on the bottom never let loose.  Now I have this, with the left slider in my bench vise waiting for an idea.

And I'm hoping I don't have to worry about that buffing of the chrome.
It appears to be below the seal.

[montmil]

Rob, did you attempt to loosen and remove the 6mm Allen screw before removing the top[ parts and spring?   Monte

[Rob Valdez 79 R65]

Rob, did you attempt to loosen and remove the 6mm Allen screw before removing the top[ parts and spring?   Monte

Yes.  It just turned, as expected, but nothing to do with loosening.

[Rob Valdez 79 R65]

NEW QUESTION:

When I release the pinch bolts holding the fork legs, how do I break the fork legs free from the grip of the triple clamp?

[Rob Valdez 79 R65]

OLD QUESTION RESOLVED:

I turned the fork slider upside down (oil comes out!) so I could put the 13mm "fastener" back onto the damper rod, and I tightened it down pretty good.

Then I concentrated all my physical and psychic energy toward breaking the allen screw loose.

It worked!!!


Just keep fiddlin...

[Barry]

To release the stanchions from the triple clamps I made some hardwood wedges and tapped them into the slots.

[montmil]

To release the stanchions from the triple clamps I made some hardwood wedges and tapped them into the slots.

Very THIN, tapered wedges and do not tap any more than absolutely necessary!   Monte

[Bob_Roller]

If that allen head bolt refused to loosen up, what would your options be, drill the head off of the bolt ?

The allen head bolt is made from aluminum, correct ?

Maybe another one of those parts, to apply anti-seize to upon reassembly !

[montmil]

Rob, a quick question for you...  Did you have the sometimes present and sometimes missing "bumpers" in the damper assembly? Looks like a big, fat, flat-sided O-ring of black rubber. Replacemnts from Motobins are now fabricated of nylon. A photo would be nice ...

When I rebuilt the 81's front end, there was no rubber part, just a messy collection of sludge in the very bottom of the lower legs.  

Monte

[Bob_Roller]

Monte,
When I was in Lowe's Home Improvement Center, a month or so ago, when you mentioned the 'wave' washers, I saw clear thick plastic 'washers' that looked like they may work in this application .

May want to check it out the next time you're in there .

[montmil]

Monte,
When I was in Lowe's Home Improvement Center, a month or so ago, when you mentioned the 'wave' washers, I saw clear thick plastic 'washers' that looked like they may work in this application .

May want to check it out the next time you're in there .

I have the "bumper" parts from Motobins. Just wondering if your bike's damper assembly had them in place.   Monte

[Bob_Roller]

The '81, didn't have them, just the black goo in the bottom of the fork, the LS, hasn't had the forks apart yet, but with 91,000 miles on it, I'd go out on a limb, and say they aren't there either .

[montmil]

Dang it! I was hoping to eliminate the occasional topping out of the forks. :-?   Monte

[Rob Valdez 79 R65]

Rob, a quick question for you...  Did you have the sometimes present and sometimes missing "bumpers" in the damper assembly? Looks like a big, fat, flat-sided O-ring of black rubber. Replacemnts from Motobins are now fabricated of nylon. A photo would be nice ...

When I rebuilt the 81's front end, there was no rubber part, just a messy collection of sludge in the very bottom of the lower legs.  

Monte

One leg had some goo (chunks, really) and no bumper ring, while the other leg was relatively clean and the bumper ring in it looks like it could be reused.

My new bumper rings are red in color.

I think this answers my question (never posed here, I don't think), of why my fork legs were un-even when I pulled the front axle out!

[Rob Valdez 79 R65]

If that allen head bolt refused to loosen up, what would your options be, drill the head off of the bolt ?

Not an option.  The damper rod would just spin.

The allen head bolt is made from aluminum, correct ?

NAW!  Couldn't be!  The one coming up from the bottom of the leg, right?  Hardened steel, I'm sure.

Maybe another one of those parts, to apply anti-seize to upon reassembly !

I think I would use some blue locktite on the threads at the top of the damper rod, that the 13mm hex fastener/oil gallery/shim holder screws onto.

You could put anti-seize on the threads of the big allen screw in the bottom, but I don't think I will.  I don't want that stuff getting in my oil.
I'll get pictures.