All Things Moto! Dirtbike Forums

Go Back   All Things Moto! Dirtbike Forums > Dirt Bike - ATV - Suspension Forums > Dirt Bike Suspension Tuning

Reply
 
LinkBack Thread Tools
  #1  
Old 01-29-2014, 11:30 AM
gusco's Avatar
Expert Class
 
Join Date: Apr 2013
Last Online: 11-08-2018 08:12 AM
Location: South Texas
Posts: 979
Default Budget rebuild

     

I'm looking to rebuild my suspension on a budget. I've got: Pivot Works fork kit, All Balls rear shock seal kit, 3 32oz bottles of 5wt Honda Fork oil, a bladder, a 46/50mm fork cap wrench, and a rubber stopper (the one on there is GONE). Anything else I might need aside from a grinder? BTW I know there are better brand of components out there, but I'm trying to do this as cheap as possible while still improving on the sticky feel the forks have now, as well as not having any clue when was the last time these 14 year old components were serviced.
Reply With Quote
  #2  
Old 01-29-2014, 02:14 PM
gusco's Avatar
Expert Class
 
Join Date: Apr 2013
Last Online: 11-08-2018 08:12 AM
Location: South Texas
Posts: 979
Default

BTW I've got these items in my cart online, not purchased. Hence the post and request for feedback before placing the order.
Reply With Quote
  #3  
Old 01-31-2014, 09:38 AM
Randog Leader's Avatar
Pro Class
 
Join Date: Feb 2012
Last Online: 10-07-2015 11:35 AM
Location: Birmingham, AL
Posts: 1,643
Default

Ha-ha! "Budget"?

You will find all kinds of fun things that need replacing when you get into it. Especially the forks. Be sure to check the fork bushing very carefully for the teflon to be intact. Those are usually shot, along with the seals. I would replace all of the O-Rings, too. They shouldn't set you back that much.

I did a short blurb about the issues that I ran into when I rebuilt my rear shock (SHOWA). Do a search in this area for the skinny.
Reply With Quote
  #4  
Old 01-31-2014, 10:56 AM
gusco's Avatar
Expert Class
 
Join Date: Apr 2013
Last Online: 11-08-2018 08:12 AM
Location: South Texas
Posts: 979
Default

According to the Pivot Works video I saw about their kit on youtube, the kit includes all the bushings, o-rings, etc... I hope it does. I wanted to re-spring for my weight, but that'll probably go in the next time a have to rebuild. I honestly don't think my riding skills are up to par for justifying the expense at this point.
Reply With Quote
  #5  
Old 01-31-2014, 03:30 PM
Randog Leader's Avatar
Pro Class
 
Join Date: Feb 2012
Last Online: 10-07-2015 11:35 AM
Location: Birmingham, AL
Posts: 1,643
Default

Product Plug: Maxima Supension Clean

This is great stuff! It cleans amazingly well, dries quickly with no residue, and has a wonderful smell.

What kind of forks do you have? Twin-Chamber, conventional, or cartridge?

I have some tips once I find out what kind you have.

Last edited by Randog Leader; 01-31-2014 at 03:30 PM. Reason: Duh
Reply With Quote
  #6  
Old 01-31-2014, 03:45 PM
stevo450's Avatar
ATM! Pro Class
 
Join Date: Aug 2012
Last Online: 01-31-2017 08:35 AM
Location: South Australia
Posts: 3,709
Default

Save up and get the right spring rates..... You won't regret it!!!

---------- Post added at 08:15 AM ---------- Previous post was at 08:13 AM ----------

Check out these too.....

Reply With Quote
  #7  
Old 01-31-2014, 04:15 PM
gusco's Avatar
Expert Class
 
Join Date: Apr 2013
Last Online: 11-08-2018 08:12 AM
Location: South Texas
Posts: 979
Default

Quote:
Originally Posted by Randog Leader View Post
Product Plug: Maxima Supension Clean

This is great stuff! It cleans amazingly well, dries quickly with no residue, and has a wonderful smell.

What kind of forks do you have? Twin-Chamber, conventional, or cartridge?

I have some tips once I find out what kind you have.
I have whatever is stock on a 2000 CR250R. I believe they are showa twin-chamber.

---------- Post added at 04:15 PM ---------- Previous post was at 04:12 PM ----------

Quote:
Originally Posted by stevo450 View Post
Save up and get the right spring rates..... You won't regret it!!!

---------- Post added at 08:15 AM ---------- Previous post was at 08:13 AM ----------

Check out these too.....

SKF Fork Seal Demonstration vs Stock Seals - YouTube
I know I won't regret it, but with baby #3 on the way I just need something to ride and get my fix... I'm nowhere near even being able to race. Once I feel confident in my ability to get around the track, I'll probably invest in the right springs, an exhaust, and reeds. But like I mentioned, I feel like I'm far from that. I've really only got MAYBE 30 laps of experience at our local track.
Reply With Quote
  #8  
Old 01-31-2014, 04:33 PM
Randog Leader's Avatar
Pro Class
 
Join Date: Feb 2012
Last Online: 10-07-2015 11:35 AM
Location: Birmingham, AL
Posts: 1,643
Default

I don't know about that video. I can get that same effect with worn stock seals. Also, there is no friggin' oil in there, yet. That makes a BIG difference. I would prefer that the seals are tight over having them slip and slide while dry.

---------- Post added at 04:33 PM ---------- Previous post was at 04:17 PM ----------

SO, just off of the top of my head:
  • Loosen both the upper cap and lower rebound bolt while the fork legs are still installed in the bike
  • Count your clicker settings (if they were worth a crap to begin with) and back both the compression and rebound clickers all of the way out (SOFT) counter-clockwise
  • After removing the rebound assembly bolt, CAREFULLY guide the cartridge back into the fork leg as it is under much pressure and can damage the fine threads if you let it snap back
  • Forks that have not been disassembled before can have Loctite on the threads and be a BEAR to remove, so be aware
  • You can lightly install the axle into the fork legs for better leverage if the bolts are giving you problems and also to torque back down
  • Go ahead and replace the fluid in the inner chamber while you have it apart
  • If replacing the oil in the inner chamber, bleed the cartridge carefully and test by pushing the rod all of the way in and then verify that it extends all of the way out when held horizontally
  • Before sliding the forks apart, apply a little heat with a torch or heat gun - it will reduce the damage to the bushings
  • Check the Teflon on the bushings and replace if the Teflon is worn through and/or if the copper coating is more than 3/4 gone
  • Clean all parts THOROUGHLY in a parts washer or equivalent and follow with either brake or contact cleaner OR my favorite: Maxima Suspension Clean
  • Replace all O-Rings unless new - cost is minimal while failure is critical
  • Carefully inspect the tubes and feel for nicks or burrs - these can be buffed with emery cloth and followed with cleaner to remove particles
  • Even if you can't feel any damage, go ahead and polish the tubes with the emery cloth and follow with the cleaner
  • Apply seal grease or equivalent to the insides of the seals and wipers
  • Use either a seal bullet or plastic bag to protect the seals when installing
  • Be sure to back the jam nut all of the way back so that there is a gap after installing the rebound adjustment assembly, then tighten the jam nut against it

Reply With Quote
  #9  
Old 01-31-2014, 05:25 PM
gusco's Avatar
Expert Class
 
Join Date: Apr 2013
Last Online: 11-08-2018 08:12 AM
Location: South Texas
Posts: 979
Default

Thanks a million!
Reply With Quote
  #10  
Old 02-04-2014, 07:23 PM
gusco's Avatar
Expert Class
 
Join Date: Apr 2013
Last Online: 11-08-2018 08:12 AM
Location: South Texas
Posts: 979
Default

I got started on the forks tonight (took a little break from my research paper). The oil was DARK, like used motor oil. There is also a gouge on the outer tube that looks like it may have come loose inside the triple clamps at some point.
The Tusk tool I got does not have the right size wrench to take out the inner cartridge. Does anyone know what size it is? I may just borrow a large socket from my mechanic... It also didn't fit between the cap and the bar mounts so I let the tubes down halfway and then used just the bottom triple clamp to hold the tube in place while I undid the nut on bottom and the cap.
Reply With Quote
  #11  
Old 02-05-2014, 08:36 AM
Randog Leader's Avatar
Pro Class
 
Join Date: Feb 2012
Last Online: 10-07-2015 11:35 AM
Location: Birmingham, AL
Posts: 1,643
Default

Sounds good so far. If the gouge is on the outer tube towards the top near the triple clamps, I wouldn't worry about that. It's what the inside looks like that is vital. Large dents that may hinder the sliding of the inner tube are another thing to check for.
Reply With Quote
  #12  
Old 02-05-2014, 09:52 AM
gusco's Avatar
Expert Class
 
Join Date: Apr 2013
Last Online: 11-08-2018 08:12 AM
Location: South Texas
Posts: 979
Default

It did slide fine... except for what feels like a bit of grinding between the bushings. Luckily, the kit comes with new ones and I hope it's just that.

---------- Post added at 09:52 AM ---------- Previous post was at 09:51 AM ----------

Anyone know what I can use to get that inner cartridge out? The forks are Showas off a 2000 CR250R.
Reply With Quote
  #13  
Old 02-05-2014, 02:02 PM
Randog Leader's Avatar
Pro Class
 
Join Date: Feb 2012
Last Online: 10-07-2015 11:35 AM
Location: Birmingham, AL
Posts: 1,643
Default

Here is a decent tutorial. They are KYB forks but the methods are nearly identical:

Reply With Quote
  #14  
Old 02-05-2014, 10:10 PM
gusco's Avatar
Expert Class
 
Join Date: Apr 2013
Last Online: 11-08-2018 08:12 AM
Location: South Texas
Posts: 979
Default

Thanks. I've studied several videos to try to get this done right. I took them apart today, and hope to clean and reassemble with new o-rings, bushings, seals, and fresh oil tomorrow.
Reply With Quote
  #15  
Old 02-06-2014, 09:17 AM
Randog Leader's Avatar
Pro Class
 
Join Date: Feb 2012
Last Online: 10-07-2015 11:35 AM
Location: Birmingham, AL
Posts: 1,643
Default

Very wise. Be sure to check the steering stem bearings for slop, also.
Reply With Quote
  #16  
Old 02-06-2014, 09:40 AM
1989kawasaki's Avatar
Expert Class
 
Join Date: Sep 2011
Last Online: 07-09-2017 12:12 AM
Location: Pickering (near Toronto)
Posts: 526
Default

Budget? I wanted to give my 500 a cheap makeover and ended up paying over 600 dollars lol. Ain't no such thing as budget
Reply With Quote
  #17  
Old 02-06-2014, 10:43 AM
cowboyona426's Avatar
JOATMON
 
Join Date: Feb 2003
Last Online: 11-15-2018 11:27 AM
Location: Newport, WA, USA
Posts: 9,495
Default

Quote:
Originally Posted by 1989kawasaki View Post
Budget? I wanted to give my 500 a cheap makeover and ended up paying over 600 dollars lol. Ain't no such thing as budget
That IS a cheap makeover. I'm into my 500 well over that amount and still have a lot more left to do.
Reply With Quote
  #18  
Old 02-06-2014, 11:37 AM
Randog Leader's Avatar
Pro Class
 
Join Date: Feb 2012
Last Online: 10-07-2015 11:35 AM
Location: Birmingham, AL
Posts: 1,643
Default

No kidding. Bought my roach for $250 and have at least $1,200 into it. Probably end up with about $1,300 total. Keep in mind that some of that is for specialty tools. Worth the price and I can reuse them later.

---------- Post added at 11:37 AM ---------- Previous post was at 11:36 AM ----------

I must add that I have replaced EVERY bearing and seal from the motor to the suspension.
Reply With Quote
  #19  
Old 02-06-2014, 11:42 AM
cowboyona426's Avatar
JOATMON
 
Join Date: Feb 2003
Last Online: 11-15-2018 11:27 AM
Location: Newport, WA, USA
Posts: 9,495
Default

I could have gotten the 500 rideable for a little less than I'm into it now, but I decided rather than pick away at the problems as they come I'd go through everything, replace what needed it, upgrade a few things, and make one heck of a nice bike out of it. So far one of the big ticket items was the suspension components from a 98 CR500 which are a considerable upgrade from what I had. It's also going to get the high dollar Service Honda ignition because it's really the only thing out there capable of providing adequate, reliable lighting on a 500.
Reply With Quote
  #20  
Old 02-06-2014, 12:16 PM
1989kawasaki's Avatar
Expert Class
 
Join Date: Sep 2011
Last Online: 07-09-2017 12:12 AM
Location: Pickering (near Toronto)
Posts: 526
Default

Quote:
Originally Posted by cowboyona426 View Post
That IS a cheap makeover. I'm into my 500 well over that amount and still have a lot more left to do.
For my 17 yr old self that is a lot of money.
Reply With Quote
Reply

  All Things Moto! Dirtbike Forums > Dirt Bike - ATV - Suspension Forums > Dirt Bike Suspension Tuning


Thread Tools


Similar Threads for: Budget rebuild
Thread Thread Starter Forum Replies Last Post
Budget bike?! Derick15 General Discussion 5 04-20-2013 07:08 PM
85 CR 500 budget restoration jbsleddin 2-Stroke Dirt Bikes - Honda 22 05-29-2012 07:34 PM
WTB 2 Stroke 80/85cc near Pennsylvania- $900 budget SirFallsALot243 Classified Ads 0 08-01-2007 08:55 PM
Budget Quad Build 4strkepwr660R Photo & Video 1 04-06-2007 01:53 AM
Best Budget Handlebars ThuMPerCR125 General Discussion 28 08-12-2003 11:23 AM


All times are GMT -6. The time now is 09:16 AM.


Powered by vBulletin® Version 3.8.8
Copyright ©2000 - 2018, vBulletin Solutions, Inc.
Search Engine Optimization by vBSEO 3.6.0 PL2
Copyright ©2002-2017, JDub Consulting, Inc. All Right Reserved.