WP4860 Fork Service For Dummies

[Ji Gantor]

A tool that is not totally required but saves time is the fork oil level device.
Geoff Ballard sells them for about $35.00 and I can not tell you how many times I have used this one.

Tight nuts

Ji

[Ji Gantor]

The pin spanner I use is made in Japan by Super.
They sell replacement pins that have two different diameters.
I purchased a few more and lathe them to the size I require.
This is the best one I have found. It cost about $120.00 but it works on all pin hole nuts.
So many people just grab a screw driver and thump it with a hammer similar to the castle nut on a shock pre load.
The right tool makes the job fun and leaves no trace.

Tight nuts

Ji

[Ji Gantor]

The oil that came out was pretty thick so I think it may have been 15 or 20 w.
5 w sloshes like water.


Tight nuts

Ji

[Ji Gantor]

The Compression bolt at the bottom of the fork is made of aluminium.
The second fork I serviced today gave a little problem when we discovered that the previous owner had rounded all the corners on the hex.
This bolt houses all the compression shims so if it won't come out there is a real issue.
I changed over from a standard 12 point socket to a 6 point socket.
The six point sockets grab more of the hex than the 12 pointer.
The 6 point socket did the job and we were able to strip the fork.
Both these sockets are 19mm.
I rang and ordered a new bolt from KTM, it will take a week to get here and cost $116.00.

Tight nuts

Ji

[firko]

Are these used for your tight nuts Robert?

[Ji Gantor]

The two sockets above that I used are Snap On.
Snap On make some really great sockets which are cheaper than Stahlwille.
Of course Stahlwille are aircraft grade where Snap On is not, but they are great to work with just the same.

Tight nuts

Ji

[Ji Gantor]

Hi GOD,
The hands in the images are my hand models.
My hands are all wrinkly, hairy and arthritic no good for pictures, but of course you would know that.
The lead does have exposed insulated wires, thank GOD, I will get my sparky to fix that next time he is passing.

World Peace

Ji

[Puppy porn]

good observation GOD. i would never have picked that one up. and by jove is it that cold over there that you need to wear thermals??

[maicomc490t]

When separating the top and bottoms it is a good idea to heat the top tube with a HEAT GUN (not gas or oxy) until they are uncomfortably hot ie require gloves to handle. This allows the bushes to slide out more freely as they are a light interference fit and the mild heat from a heat gun provides some expansion so the sliding action doesn't belt the shit out of the edge of the bushes. Usually they pretty well fall apart.

On the subject of spanners, a thread in itself, yep Stahlwille are my favourite QUALITY brand. Snap On rhymes with Crap On and for what they ask for their tools, no matter how good they supposedly are, the prices cannot be justified! Up to 19mm Ballard T's also do a pretty good job and are six hex.

What is it with 'tight nuts' by the way - you can fix that with the right woman you know!

Dave Mac 

[Ji Gantor]

Hi Dave Mac,
That is a great add to this thread.
Snap On are expensive but Stahlwille sockets are off the chart.
That is why I have both.

Tight nuts

Ji

[maicomc490t]

Hey Ji

Ebay + Stahlwille equals affordable good gear.

Ebay + Snap On ? Well scored a brand new Snappy torque wrench for next to nothing so not all bad...........

Dave Mac 

[Ji Gantor]

I get brand new Snap On 1/2" socket set on Ebay for $150 same in Stahlwille is about $400.00.
I plugged away a few years back on Ebay US and purchased all my tools cheap. It took a while but it was worth it.
I do like Stahlwille open end spanners they are light and thin they also have a different attack angle which in tight engine areas is a big help.

Tight nuts

Ji