Front Fork Rebuild

[ryanschoebel]

Hey all, Im looking to take my 85 100 into a shop to have the front forks redone. they have been leaking as long as ive owned the bike. I just want the forks redone, not upgraded,swapped or anything, but i dont know how. What parts would i need to make sure i redo them correctly? So i need to replace springs, and bushings?Im not sure what the stock parts would be, and most of what i saw on RPM were upgrade parts.

Any advice??

Thanks, Ryan

[andyoutandabout]

Well, not to demotivate you, but working on the forks was probably my least favorite job and one that required specific tools that I didn't have. Consequently I now run them to RPM and spend a bit of cash to save a lot of heartache. Then again I'm lucky enough to live just two hours away, so this really makes sense for me. I note you live in Arizona, so google the route and see what you think.
When watching Randy change the forks seals it was very obvious that he was able to assess the parts needed as opposed to my scatter purchase of various bits from the parts manual. Paying for this engineering knowledge worked out usefully cheaper than a random collection of unnecessary parts.

Andy

[ryanschoebel]

Then again I'm lucky enough to live just two hours away, so this really makes sense for me. I note you live in Arizona, so google the route and see what you think.


Andy

Hey Andy, i did think about it, but the only time im going in that area would possibly be the upcoming WCR, and i was hoping to do this before the many hour ride over. Im going to have a shop do it, i just dont know what parts i need to order from RPM for them to install. 

[racerrad8]

Ryan to be on the safe side, you should order the fj fork rebuild kit. It has all of the bushings and seals needed for a general rebuild.

There are other items that you might also want to think about.

The copper washers used to seal the bottom of the forks and the fork drain and damper rod screw plastic washer/gaskets.

Also, if you do take it to a shop, you need to include the gysm. If they don't have it, I am 100% confident they will not do the rebuild properly; especially if it was done incorrectly by the previous person that worked on them.

In all of my years of working on the fj. The only set of forks that I have ever seen that were correct were never taken apart. It was a set that had never been worked on by anyone other than the Yamaha factory build.

Keep in mind, you can always ship them up here and I can build then for you.

I will have Robert attach links to the above recommended items tomorrow morning.

Randy - RPM

[Mike m]

Does RPM inspect and rebuild forks?

[Mike m]

Never mi d I see rpm does rebuild forks.sorry shoulda read the thread before asking .

[Mike Ramos]

Well, not to demotivate you, but working on the forks was probably my least favorite job and one that required specific tools that I didn't have. Consequently I now run them to RPM and spend a bit of cash to save a lot of heartache. Then again I'm lucky enough to live just two hours away, so this really makes sense for me. I note you live in Arizona, so google the route and see what you think.
When watching Randy change the forks seals it was very obvious that he was able to assess the parts needed as opposed to my scatter purchase of various bits from the parts manual. Paying for this engineering knowledge worked out usefully cheaper than a random collection of unnecessary parts.

Andy

Greetings,

Have to agree with the cost effectiveness of having the RPM shop rebuild the forks - also, not knowing the mileage on your FJ, perhaps all that is needed are seals (?) and not a complete rebuild - for sure they will let you know the verdict.

While I live considerably farther from RPM than Mr. Andyoutandabout I also live considerably closer to RPM than Arizona - yet it would seem prudent & worth the shipping costs to know the servicing was done correctly. 

Ride safe,

Midget

[chiz]

I'm sorry but I don't share any of the apprehension you folks do about building forks. Having said this the modern forks of today I'm guessing would or might be more than tricky.
Don;t see what the problem is just get the parts and do it bushings seals etc etc take em apart fix and put together that's it. Just recently I did a set of KZ 1000"S and the damper rod started spinning on one, just stuck a long rod down the fork and pushed hard while using the rattle gun on the bolt.... instant joy.
    Sorry about sounding a bit irritating my work satisfies my needs may not be up to Randy's precision and expertise but works for me so far.
Lez

[ryanschoebel]

Greetings,

Have to agree with the cost effectiveness of having the RPM shop rebuild the forks - also, not knowing the mileage on your FJ, perhaps all that is needed are seals (?) and not a complete rebuild - for sure they will let you know the verdict.

While I live considerably farther from RPM than Mr. Andyoutandabout I also live considerably closer to RPM than Arizona - yet it would seem prudent & worth the shipping costs to know the servicing was done correctly. 

Ride safe,

Midget

Hey Midget,

I have been talking oto the guys down at RPM today, and thats just what im going to do. Not only do i know that they can do it right, and that i can trust the work, but their prices are also better than anything in my area haha. So im going to buy a motorcycle lift tonight so that i can remove the forks, and ill be sending them out in the next few days.

[chiz]

Look I know the postage/ shipping in the US is very reasonable even so I can't imagine two forks being cheap and the price of parts $100.00 or so plus labour costs to me this is not cost effective. When for the price of parts you can get the job done what point am I missing. On the other hand when I found out years ago that there are actually tons of folks that don't work on their bikes I was bowled over as to me working an fixing your own stuff is part of the game.
Lez 

[Mike Ramos]

Look I know the postage/ shipping in the US is very reasonable even so I can't imagine two forks being cheap and the price of parts $100.00 or so plus labour costs to me this is not cost effective. When for the price of parts you can get the job done what point am I missing. On the other hand when I found out years ago that there are actually tons of folks that don't work on their bikes I was bowled over as to me working an fixing your own stuff is part of the game.
Lez 

Howdy Chiz!

There is no argument, just a discussion.

Not sure if you are missing anything; and as you state you have the talent to complete the job.

However for others, while admittedly there is a point of diminishing return, the peace of mind that the job is done correctly also has a value.

In respect of your valued opinion, engine oil is very important: Is there a particular oil you can recommend...? 

Oh yes, always ride safe,

Midget

[Pat Conlon]

Lez, no argument from me, you are correct, it's cheaper if you just buy the parts and do it yourself
(if you can)
However, if you don't have the tools or knowledge or desire, why not pay someone to do it for you?

The point is, if you are going to pay your hard earned money for someone to rebuild the forks on your 33 year old bike, why not choose someone who actually knows what the fuck they are doing?

Sure, you could save yourself shipping costs, if you had someone local who could do it correctly...key words being "..who could do it correctly".

The first time I did my old damper rod forks the Yamaha dealer screwed up. Both seals leaked.  Took it back, and they screwed up again and did not get the adjuster rods (both) positioned correctly...took it back again and they over tightened and cracked both my fender tabs.....WTF. They had to buy me a new fender.
Don't get me started on dealers.

I can now do the forks myself, but not back then...I would have given my right nut to have a resource like RPM available to me back then, unfortunately Randy was still in high school.

Young Ryan is 5 hours away from me (one way)  if he were closer I would show him how to do his forks, but alas not.....I think shipping them to RPM is the right move.

I know money is tight, but I do wish Ryan would at least invest in a new set of progressive springs. Those 33 year old oem springs were soft the day they left the Yamaha factory and by now, are totally sacked out.
Add $100 more to the project for some fresh progressive springs would IMHO be a good call.
https://www.progressivesuspension.com/product/1465/fork-spring-kit

[ryanschoebel]

Lez, I am perfectly happy to do my own work. But only when I have the right knowledge, tools,and ability to do so. I would rather ship them to RPM, and have it done right, than put out the extra money for tools, and what not to do it myself, and still risk having it wrong. Right now, my cost is looking something to the tune of 350 to 400 after shipping to have RPM do this for me. And that's if I don't go progressive springs, which I may. (Good tips Pat, I did some extra research on it!!) I was getting quotes in my area of $300 for JUST labor. I would much rather have it done by professionals, who know this bike in and out, and have so many people here sing glowing praises for them. If I pay a but more, but have peace of mind while riding, it's worth every cent. While I would love to learn how to do everything I can on this, it's just not practical for me at this point.

[FJ_Hooligan]

All you need is a few pages out of the manual that show you how to disassemble the forks

Here are instructions for installing the parts and how to make the "special tools" for about $10

http://www.fjowners.com/index.php?topic=17417.0

[chiz]

I got to say I have to eat some humble pie over here. My machinist/ millright bud at the steel mill did a wonderfull precise as possible jog of mating a KZ650 and disc brake wheel and swingarm to a BSA rocket3 to an output sprocket mounted in the engine lining everything up with an array of carefully machined spacers and  Kz 650 double disc front to a KZ1000 front end a job in my wildest dreams I could not dream of doing so there.
Anyway points well and all taken .....cheers