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2015-07-26 ? Rebuilt Fork is 1" Longer than the Other ?

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published by dcarver on Tue, 07/28/2015 - 20:06
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2007 Suzuki DL650A - Wabs

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Posted 26 July 2015 - 08:12 AM

Sooooo then.. rebuilt both front forks on my DL-650. Went swimmingly well... no GixxerJason syndrome, got the rebuilts installed in the triple trees, .....and then.... struggled for 10 minutes to make the front fender fit..

 

No dice. Holes not even close between the two sides. Looking at the axle alignment, it's clearly obvious that 1 fork is ~1 inch longer than the other!

 

WTFO?

 

Both forks went together smoothly, both have good 'action'. The right leg was easier, however to get the cap screwed back into the slider...less spring tension.

 

Now then you techies... Can you figure this out? 

 

I have the answer.....

 

Consider this a fun mental forking excercise?

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    #2 radiummadman

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    Posted 26 July 2015 - 08:32 AM

    too mush forking oil ???

    #3 FJRay

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    Posted 26 July 2015 - 08:38 AM

    The first question on the trouble shooting flow chart is.

     

    Did YOU touch it???

     

    From there the answer is simple so just approach it with a simple mind. You are qualified for that. 

     

    Have a nice day Don I'm trying to be a carpenter today so Lapine is in trouble.

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    #4 Fontanaman

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    Posted 26 July 2015 - 10:01 AM

    *
    POPULAR

    The first question on the trouble shooting flow chart is.

     

    Did YOU touch it???

     

    From there the answer is simple so just approach it with a simple mind. You are qualified for that. 

     

    Have a nice day Don I'm trying to be a carpenter today so Lapine is in trouble.

     

    Here is the troubleshooting flow chart......  smile.png

     

    FlowChart.JPG

    #5 08FJR4ME

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    Posted 26 July 2015 - 10:11 AM

    Air pressure?

     

    Dave

    2008 FJR1300A, 2005-Honda XR650L-2001 Honda Rubicon 4X4     WynPro Custom MC Products , 

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    #6 yamafitter

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    Posted 26 July 2015 - 10:29 AM

    First Question:

    How many leftover parts were there after YOU completed the rebuild? 
    cfrlogo-2-1.jpgNAFO-2010pinrev1.jpgcfr2010.jpgwcrlogo.jpgCFR2013signature_zpsf3d5251e.jpg
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    #7 rushes

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    Posted 26 July 2015 - 10:33 AM

    I'd fire the mechanic....

     

    :)

    #8 bluesdog

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    Posted 26 July 2015 - 10:38 AM

    Two 1/2" spacers in one; none in t'other?

    His Indian name is 'Barks-At-Harleys'

     

     

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    #9 yamafitter

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    Posted 26 July 2015 - 11:59 AM

    Two 1/2" spacers in one; none in t'other?

     

    I think we have a winner but it is also maybe item #5 got installed upside down....

     

    DR%20Fork-L.png

     

    On the FJR however when that piece gets upside down the bolt isn't long enough to reach and you can't tighten the bolt up.

    Ask Ray how I know this.

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    #10 rushes

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    Posted 26 July 2015 - 12:03 PM

    Drinks AFTER the bike is back together....

    :)

    #11 FJRay

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    Posted 26 July 2015 - 02:20 PM

    If the rebound spring got on the wrong side of the damper rod it would make the leg longer. 

    that would be number 14 in Fitters picture.

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    #12 dcarver

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    Posted 26 July 2015 - 02:45 PM

    If the rebound spring got on the wrong side of the damper rod it would make the leg longer. 

    that would be number 14 in Fitters picture.

     

    Almost a ding ding winner winner chicken dinner!

     

    The rebound spring jumped off the inner tube when I wasn't looking. 

     

    I WAS wondering why the right fork cap installed so easily.. Very little spring compression required. fool.gif no.gif 

     

    My clue was when exercising the fork, spring and oil out, when at full extension it would go 'clunk'. Huh? Clunk? Huh? 

     

    By then, it was time to RTFM and look at pictures..

     

    Sure enough, one rebound spring mia. Found it in the leaves next to the outdoor table.

     

    It's amazing what happens when you use ALL the parts!

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    #13 Twigg

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    Posted 26 July 2015 - 02:54 PM

    I WAS wondering why the right fork cap installed so easily.. Very little spring compression required. fool.gif no.gif 

     

    Every time I ignored a "doubt" like that I end up having to do it all again. I am learning to satisfy my doubts as I go along, but it's a slow process.

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    #14 lonerider

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    Posted 26 July 2015 - 03:22 PM

     

     

     

     

    Sure enough, one rebound spring mia. Found it in the leaves next to the outdoor table.

     

    It's amazing what happens when you use ALL the parts!

     

     

     You were lucky to find it. Any time I'm so clumsy as to drop a small part in my garage, it will immediately dart to the most inaccessible crack in the floor, burrow to the very bottom, and resist all efforts to be found. Glad to hear it turned out well for you. 

    #15 Jer

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    Posted 26 July 2015 - 06:00 PM

    It is nice to know there is an expert available when it is time for a fork rebuild for my DL-650.

    Jer

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    #16 Hotboot

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    Posted 26 July 2015 - 06:16 PM

    I rebuilt a set once, Modelo Especial and a buddy were involved. I now send them to Traxxion and enjoy the Modelo while while waiting for the proper product to return.

    Too many cagers and not enough curves, get me outta here.

    #17 bluesdog

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    Posted 26 July 2015 - 06:54 PM

    Almost as annoying is when you find a small part, such as a screw or nut, on the floor near the bike just after finishing a re-assembly job.

    weirdsmiley.gif

    You can spend hours trying to figure out what you missed, until you realize the darn thing came from somewhere completely unrelated to the bike.

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    #18 gixxerjasen

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    Posted 26 July 2015 - 07:30 PM

    It is nice to know there is an expert available when it is time for a fork rebuild for my DL-650.

    Hrm, don't recall saying I was available. There is tech named after me though. I'm with hotboot on Traxxion, although I might be dumb enough to try again. biggrin.png
     

     

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