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 Post subject: Front fork question.
PostPosted: Fri Mar 29, 2019 10:50 am 
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I never did take my forks in over the winter to get new seals put in. Now, I want to try to do it. I look at partshsark and they give the exploded view with part numbers. I don’t have any idea what would be normally replaced. I’m guessing the parts I would probably need are:

92093-seal
92033-snap ring
92049-seal
92026-spacer
44065-bushing
44065a-inner bushing

Sound right, or is there more?

I already screwed the pooch by removing the forks from the bike and pulled the springs. The video I later watched left the springs in the forks so the internals wouldn’t spin while removing the bottom screw.


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 Post subject: Re: Front fork question.
PostPosted: Fri Mar 29, 2019 3:05 pm 
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Location: New Brunswick Canada
I have not done mine, but everyone I spoke to that have done them suggest an impact gun to remove the bolt in the bottom.
Re-attaching, follow the manual

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Ken in N.B.
"Be who you are and say what you feel"
"Because those that matter don't mind and those that mind don't matter."
"Trust God that you are where you are meant to be."

2001 Voyager ZG1200 (XII) (present)
1984 Voyager ZN1300 (past)


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 Post subject: Re: Front fork question.
PostPosted: Sat Mar 30, 2019 5:33 pm 
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Ken in NS wrote:
I have not done mine, but everyone I spoke to that have done them suggest an pmpact gun to remove the bolt in the bottom.
Re-attaching, follow the manual


yep, that got it out. Thanks for the tip. The little impact didn't get it, but the big one did.

Looks to me like seals would have been all I needed if I wouldn't have lost a couple parts. Didn't know I did it, but what I have doesn't match the picture. Nice.


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 Post subject: Re: Front fork question.
PostPosted: Wed Apr 03, 2019 5:43 pm 
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Location: AKRON OHIO
If your springs have ever been changed before it's likely that someone else left those parts out because there wasn't enough room to put them back. Many times the new springs are much taller than the originals. I replaced my seals a few years back. It was not difficult until reassembly. It took about five times loosening and tightening the forks before the wheel would spin freely when done.

Sounds like you have the seal installation handled. I will try to be more attentive in the near future in case you have any more questions. I was on vacation when this was originally posted.

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"DIRTFT" Do It Right The First Time
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 Post subject: Re: Front fork question.
PostPosted: Thu Apr 04, 2019 10:35 pm 
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Thanks Count. I don’t expect you to pass up a vacation for fear I’ll try to fix something. The manual does a good job of showing some of the parts that I’m unsure of. One part I did find in the gravel afterwords was the little spring that goes in the bottom. Only thing I don’t have now is a washer that goes with the short spring.

Now I have to take the other one apart. Keep it upright Seems to be a good idea.


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 Post subject: Re: Front fork question.
PostPosted: Sun Apr 07, 2019 7:47 pm 
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Got everything put back together. Too muddy to ride and I'll be gone all week, so have to wait for the first ride. Did push the front end down several times and it didn't leak.

Either I don't know how to look at the picture in the manual, or the pic is wrong, but neither fork had what appears to be a washer above the short spring on what they call the cylinder. It went back together kinda easy, and that scares me a bit. If this works, I'll do the other set.


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 Post subject: Re: Front fork question.
PostPosted: Sat Apr 20, 2019 10:40 pm 
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They still leak.

Not bad at all, but they do.

The manual says to put the "guide bush" with the slit facing left or right. I don't get what difference that could make, but on each fork, I put the slit so it faces out. I really don't see what else a guy could do to muck this task up.

The new ones I put in were labelled as leak-proof. They are a soft, flexible rubber and come with a composite "washer" that sits between the factory washer and the new seal. I've got a set now from All Balls, and they are just like the ones I pulled out. Not flexible and I can see the springs.


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 Post subject: Re: Front fork question.
PostPosted: Sun Apr 21, 2019 6:27 am 
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The fork seals have 3 lips on the inside face, 2 at one end and 1 at the other end. The correct way is with the 2 sealing lips on the bottom/lower installed side of the fork seal, and if one puts them in with the single lip on the bottom they will leak. Not a lot but it's still a leak. I made this mistake once and had to redo one fork leg as the other was fine. After the redo it was oil tight. Just a thought,
Dave


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 Post subject: Re: Front fork question.
PostPosted: Sun Apr 21, 2019 7:27 am 
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Thanks Triton. I see what you are saying.

The leak proof set didn't have any lips like that. It has a flat side that goes against the composite washer, and the other side is open with ribs or segments inside. No springs. The I.D. of the seal is smooth. They are nothing like what I took out or the new set.


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 Post subject: Re: Front fork question.
PostPosted: Sun Apr 21, 2019 1:49 pm 
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Location: AKRON OHIO
You might use this as a reference as well.

http://www.abbikeboard.com/jeff/spring/spring.html

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The Count of Multichrome "Bill"
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"DIRTFT" Do It Right The First Time
2002 Voyager XII
:CBCGW:

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Cell Phone: Dg3.jpg Dg3.jpg Dg0.jpg - Dg5.jpg Pg1.jpg Dg5.jpg - Dg0.jpg Dg9.jpg Dg3.jpg Dg4.jpg


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 Post subject: Re: Front fork question.
PostPosted: Sat May 04, 2019 5:09 pm 
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Thanks Count. I have used that in the past. I never have drained oil out the bottom like that though. Something else I just noticed was his oil level measurement at the bottom of his page. He says 160mm = or - 2 mm. I have always done 145. That is what I have written in the manual, but I don't recall why.

I think I can finally declare victory though. I have roughly 700 miles on the All Balls seals and it's all dry. Both sides.


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 Post subject: Re: Front fork question.
PostPosted: Sat May 04, 2019 8:31 pm 
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What a good feeling it is when a job goes the way it's supposed to.


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 Post subject: Re: Front fork question.
PostPosted: Tue Jun 11, 2019 7:43 am 
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Location: New Brunswick Canada
Good show, I completed my overhaul including bushings last week.
Received good advice from both Triton and the Count

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Ken in N.B.
"Be who you are and say what you feel"
"Because those that matter don't mind and those that mind don't matter."
"Trust God that you are where you are meant to be."

2001 Voyager ZG1200 (XII) (present)
1984 Voyager ZN1300 (past)


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 Post subject: Re: Front fork question.
PostPosted: Wed Jun 12, 2019 5:13 pm 
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That's great that you got it all done. It is a daunting task until you get in there and figure it out. Glad it went well.

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The Count of Multichrome "Bill"
:party:
"DIRTFT" Do It Right The First Time
2002 Voyager XII
:CBCGW:

b.gif i.gif l.gif l.gif gif_23.gif n.gif a.gif g.gif y.gif t.gif o.gif o.gif l.gif s.gif gif_21.gif c.gif o.gif m.gif
Cell Phone: Dg3.jpg Dg3.jpg Dg0.jpg - Dg5.jpg Pg1.jpg Dg5.jpg - Dg0.jpg Dg9.jpg Dg3.jpg Dg4.jpg


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