Help! Front Forks

[Deadly_Viper]

Hi,

I know I've asked this question before but I need to replace my stanchion tubes, I have the new ones but I need to get the internal shuttle out of the old tubes.
Has anyone done this before as I am stuck??

I have tried my local bike garage but they wont help.

If anyone has changed their forks over before any help would be greatly appreciated.

Thanks

[Peteo]

Ring Revs Suspension in the midlands. John is a friend of mine and he will help you over the phone!
Ring 0121 501 3321

[Deadly_Viper]

Thanks, I shall call them on monday.

[spongy.bob]

Hi mate,

what bike are we talking about here? By shuttle, do you mean the damping rod?

Rob.

[royster81]

i helped a mate do this a few months ago, we used a bench grinder to grind the edge off the bottom where the shuttle was.

it came out pretty easy once we figured out what we had to do.

then reinserted it into the new legs and secured it with the circlip they gave with the new legs, tidy job when finished.

[Deadly_Viper]

Hi,

The bike is a VFR 400 NC24.

I have ground the ends off the old tubes but I cant seem to dislodge the shuttles, I dont want to grind off much more, in case I damage the shuttle. I have ground the rolled lip off so it is now a smooth edge which I have been told is enough, but I cant get them to budge.
I have spoken to several places now but the company that made the tubes have offered to do the work for me if I send them the tubes. Might have to do this and pay the postal costs.
I have looked for genuine tubes but I can only find one and most places cant get hold of them.
What a nightmare!

[Deadly_Viper]

I have managed to get the tubes all done by a local bike mechanic, Gary Teague, he did a good job and for a fair price too. I have assembled the forks, new seals but have hit another problem. The very bottom bolt, that is a nightmare to get out, I now cant tighten up up! It goes in so far then just keeps spinning the internals.

Have I broken something (gulp! ) or is there a special tool to use to hold the internal bit still (I have noted a star patten on the internal piston) ??

[veefer400]

Build the forks up, the spring pressure will hold the plunger rod still so you can do the bolt up...

Is there a bolt/allen head you can access on the top of the tube? May be held with several socket extensions, etc?

[spooky]

If you can find a 24 mm bolt (measured across the flats) and weld it onto a bar about 600 mm long it will work a treat. Just push the head of the bolt into the top of the damper rod and the bar into a vice or something to stop it from turning and tighten up the allen bolt. Don't forget the copper washer!
Also use it to help remove that bolt the next time you are doing the seals.

[Deadly_Viper]

Fantastic! I tried the spring prssure but it just wasnt enough. I have the copper washer

I shall head down the DIY Shop and see what I can find.

Just out of intrest can you buy a special tool for this?