Fork Question

Aussie650 · Posted: May 11, 2009, 11:29 am Post subject: Fork Question

First. sorry if this is the wrong section but think its right.
So, i changed the Fork oil on my 81 650 special. From all research there should have been removable caps to pour the oil into on the top? I had taken the forks out to clean them up. After draining them I ended up having to undo the 8mm nut on the bottom, tight sucker, and filling upside down? The top of the forks have a plastic cap and under them seem to be sealed? Anyone know what the go is? Cheers, Pete.

Retiredgentleman · Posted: May 11, 2009, 12:27 pm Post subject: Re: Fork Question

www.biker.net/81_650h_...0main.html

Click on "Forks" in the link. Item 24 is a bolt that unscrews. There is also a 3 position spring tension adjuster within the bolt. Its best to first relieve the tension by turning counter clockwise with a large flat blade screw driver. Be careful as the bolt is still under tension.

Aussie650 · Posted: May 11, 2009, 12:39 pm Post subject: Re: Fork Question

Hi Retiredgentleman, thanks for the response. I had seen that diagram previously. Unfortunately under the rubber cap there is a flat sealed cavity. No bolt or nut? ill take a pic of it when I get home in a few hours and post it? Thanks again.

jayel · Posted: May 11, 2009, 1:11 pm Post subject: Re: Fork Question

here's another look.....

Aussie650 · Posted: May 12, 2009, 2:43 am Post subject: Re: Fork Question

ok so hopefully there should be a pic? As you can see there's no nut in the top?

650skull · Support Staff Joined: Jul 19, 2007 Posts: 1186

Got me beat, never seen them like that before..........................???

Retiredgentleman · Posted: May 12, 2009, 12:11 pm Post subject: Re: Fork Question

skull is right, those are not stock forks. I see no way to change the fork spring or add oil etc. You're on your own on that set-up.

yamaman · Posted: May 12, 2009, 12:23 pm Post subject: Re: Fork Question

Mmmmm looks pretty fishy! The top of the tube, on the inside, should be threaded to recieve the cap, yours don't even seem to be threaded?

Thay also seem to be a long way up through the triple clamps, can you give us a pic of the whole front end.

I'm guessing that (if they are XS forks) someone has shortened them for some reason and somehow made their own caps.

There's not a circlip or a groove where there was one once is there? That plug has to come out somehow............ Good luck with it & keep us posted, can't wait to find out the answer! Cheers

Aussie650 · Posted: May 12, 2009, 12:35 pm Post subject: Re: Fork Question

Dang, The outer tube is obviously stock as it has all the right mounting holes along with the drain plug. It was an effort I must say. To take off the 8 mm nut at the bottom I had to compress the fork and muscle up. Still came off then just poured the oil in that way? No idea whats going on with it?

yamaman · Posted: May 12, 2009, 12:36 pm Post subject: Re: Fork Question

I just had a look at your other thread, those staunchions look like they might be longer than standard????? The bottoms seem to be XS.....

Chech the staunchions for a join, maybe some crazy barstard made an extension that screws into the standard tubes?

Aussie650 · Posted: May 12, 2009, 12:49 pm Post subject: Re: Fork Question

Will do, heres a couple of closer pics? Theres def no thread in the top but it kinda looks like there might be a circlip or slight gaps in around the edge of the sealed section? oh and when I had them off there was def no join? Maybe some after market mod? Ill have to pull them off again and check, spring length and take lots of pics.

yamaman · Posted: May 12, 2009, 1:11 pm Post subject: Re: Fork Question

I'd spray the hell out of it with CRC and clean it up in there as much as you can & have another look. It looks to me as though theres a circlip of some sort there.

After you've done that:
With the front wheel just on the ground (so there's minimal/no weight on the springs) see if you can push the cap down somehow (you'll be pushing against the spring if this GUESS is right)!

Aussie650 · Posted: August 27, 2009, 10:02 am Post subject: Re: Fork Question

Can someone measure the stock length of a Fork tube so I can compare it to mine? Im going to take them back out in a few days for another crack. 81 Special. Cheers. Pete.

pumps · Posted: August 27, 2009, 3:10 pm Post subject: Re: Fork Question

I have my tubes out and could measure if the tubes on a 77 Standard are the same.

Aussie650 · Posted: August 28, 2009, 2:23 am Post subject: Re: Fork Question

According to Mikesxs 77 to 84 had the same forks so if you could I would really appreciate it. Thanks!

pumps · Posted: August 28, 2009, 5:07 am Post subject: Re: Fork Question

This whole length correct?

5twins · Full Member Joined: Aug 05, 2006 Posts: 1616

deleted

Aussie650 · Posted: August 29, 2009, 1:28 pm Post subject: Re: Fork Question

Pumps - Was chasing the length of just the Top tube, but thanks!
5twins - Ill have a crack at your method. Just hope I dont end up wearing a plug in the face Very Happy

Appreciate the help again guys.

xsleo · Posted: August 29, 2009, 6:24 pm Post subject: Re: Fork Question

It may be easier to get some one to press down on the plug while you remove the clip. Same with the install.

Aussie650 · Posted: September 9, 2009, 7:15 pm Post subject: Re: Fork Question

Update time. Success! I pulled the forks again, drained the oil, unscrew the allen head bolt on the bottom and pulled the two sections apart. Now that there was no presure on the top plug I was able to push it down a few mm and bingo! there was a circlip. Removed the circlip and out came the top cap, a metal cylinder, spring and the other part that i have no idea what its called? I have laid it it out in order from top to bottom so you can all see. I now have three Q's.
1. What are they off? 5twins, do you still thing maybe 500 or 400?
2. How much oil do they take? should I stick with the standard amount?
3. Dont flame me bout this one, they are longer then stock, If I wanted to shorten them slighty, could i cut the metal cylinder above the spring? Im only talking 1/2".
Thanks again.

gordo · Posted: September 9, 2009, 9:45 pm Post subject: Re: Fork Question

Aussie, if it were me, I'd chuck the top tube's & get what I needed from Mike's, emulator's, spring's, tube's, seal's, & either gaiter's or the rubber cap's. 'Cause if you plan on keeping her for a few year's, you would probably want to change the fork oil once a year. Oh ya, forgot to say the cap's with the real fine thread!!!

xsleo · Posted: September 10, 2009, 1:53 am Post subject: Re: Fork Question

If your fork tubes are 35 mm, I might just replace the whole forks. There are usually a few sets on ebay. That way you would know for sure just what you do have.

Aussie650 · Posted: September 10, 2009, 2:53 am Post subject: Re: Fork Question

Thanks guys, thought about just picking up a set off ebay, but they dont cmoe up as often as they do here in Aus. Shipping from US isn't pretty. Im happy to clean these up and run them, just love to know what they are. Ill def keep my eye out for a set here in Aus in the mean time. Now that i know how to remove the top cap, it should be alot easier to change the oil.

nj1639 · Posted: September 10, 2009, 7:15 am Post subject: Re: Fork Question

When those forks are together and on the bike what is the overall length, say, from top to the middle of the axle?

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