Need help reassembling fork!

virago_81 · 02-08-2010, 05:50 PM

Hoping someone can help me out here!
So today I started installing emulators and springs on my SV. Did the left side first and everything went fine. Now I'm having trouble reassembling the other side. When I drop the damping rod and the short spring that goes under it into the tube, I can't get the bolt that goes through the end of the tube to thread into the damping rod. It's like the rod isn't going deep enough into the tube for the bolt to reach it no matter what I do. I can look down the tube throught the damping rod and see the end of the bolt, but it won't reach the threads on the rod. Has anyone experienced this before? Ideas? I spent over an hour taking it apart and putting it back together but nothing gives.

Thanks
Nick

**JiffyPark** · 02-09-2010, 08:47 AM

I've never had those particular forks apart but does the small spring need to be compressed a bit to get the rod to reach to the bolt? I've heard guys talk about the rod spinning as they try to tighten the bolt too. I guess some guys use a wooden broom stick handle to keep the rod from spinning. Let me know how it turns out since I'm interested in running emulators if I ever upgrade the forks on our SV. Might do a front end swap though since I have a few GSXR & TL setups I could use.

virago_81 · 02-14-2010, 12:28 AM

The guys on SVRider got me pointed in the right direction. There's a small aluminum part that the bottom end of the damping rod seats into. This part can't be removed without complete disassembly of the fork tube but it's loose inside the lower tube with the damping rod out. It somehow was flipped upside down or lodged so that it wasn't where it was supposed to be in the bottome of the tube. I popped it loose with a long screwdriver and got everything back together.
So now I have Racetech emulators and Sonic springs. Also installed Galfer SS front brake lines and some EBC sintered pads. Can't wait for a nice day and some free time for a proper test ride!

Wistrick · 02-14-2010, 06:58 AM

Must be something in the water. I spent 1000 on my suspenders on the VFR at GP suspension, full front fork rework and penske double clicker in the rear...Does my heart good to see people spending money on this kinda mod!!!!!!!!!!!!!

Dan

virago_81 · 02-14-2010, 07:22 AM

Quote:

Originally Posted by Wistrick

Must be something in the water. I spent 1000 on my suspenders on the VFR at GP suspension, full front fork rework and penske double clicker in the rear...Does my heart good to see people spending money on this kinda mod!!!!!!!!!!!!!

Dan

I would really love a new shock too but can't yet bring myself to drop $800+ on one.

Wistrick · 02-14-2010, 07:29 AM

I paid $777.000 to my door!!!!!!! penske double clicker

virago_81 · 02-14-2010, 07:36 AM

Hmm. It is a shame to upgrade the fork and still have a mushy rear.

**JiffyPark** · 02-15-2010, 11:08 AM

Does Bitubo make a unit for the SV? I had one on both a TLS and a TLR. Very affordable and have a good reputation at least in the TL community. I think I only paid around $450-$500 or so in a group buy. There is a member on my TL site who works for Traction Dynamics, he might be able to get me a deal on one if they make one.

virago_81 · 02-15-2010, 02:17 PM

Quote:

Originally Posted by JiffyPark

Does Bitubo make a unit for the SV? I had one on both a TLS and a TLR. Very affordable and have a good reputation at least in the TL community. I think I only paid around $450-$500 or so in a group buy. There is a member on my TL site who works for Traction Dynamics, he might be able to get me a deal on one if they make one.

My search is coming up negatory on the Bitubo. My budget would like $500 a lot better though.

02-08-2010, 05:50 PM	#1
virago_81 IR Addict Join Date: Feb 2007 Location: Plummer, ID Bikes: '06 SV650, '79 XL500S, '79 XR500R, '92 Trail Boss 250 Posts: 164 Trader Rating: 0% (0) View My Gallery	Need help reassembling fork! Hoping someone can help me out here! So today I started installing emulators and springs on my SV. Did the left side first and everything went fine. Now I'm having trouble reassembling the other side. When I drop the damping rod and the short spring that goes under it into the tube, I can't get the bolt that goes through the end of the tube to thread into the damping rod. It's like the rod isn't going deep enough into the tube for the bolt to reach it no matter what I do. I can look down the tube throught the damping rod and see the end of the bolt, but it won't reach the threads on the rod. Has anyone experienced this before? Ideas? I spent over an hour taking it apart and putting it back together but nothing gives. Thanks Nick

02-09-2010, 08:47 AM	#2
JiffyPark IR Administrator Join Date: Dec 2006 Location: Spokane Bikes: 07' Tiger, 03' DL1000 Posts: 693 Trader Rating: 0% (0) View My Gallery	Re: Need help reassembling fork! I've never had those particular forks apart but does the small spring need to be compressed a bit to get the rod to reach to the bolt? I've heard guys talk about the rod spinning as they try to tighten the bolt too. I guess some guys use a wooden broom stick handle to keep the rod from spinning. Let me know how it turns out since I'm interested in running emulators if I ever upgrade the forks on our SV. Might do a front end swap though since I have a few GSXR & TL setups I could use. __________________ I like my skin so I wear gear...

02-14-2010, 12:28 AM	#3
virago_81 IR Addict Join Date: Feb 2007 Location: Plummer, ID Bikes: '06 SV650, '79 XL500S, '79 XR500R, '92 Trail Boss 250 Posts: 164 Trader Rating: 0% (0) View My Gallery	Re: Need help reassembling fork! The guys on SVRider got me pointed in the right direction. There's a small aluminum part that the bottom end of the damping rod seats into. This part can't be removed without complete disassembly of the fork tube but it's loose inside the lower tube with the damping rod out. It somehow was flipped upside down or lodged so that it wasn't where it was supposed to be in the bottome of the tube. I popped it loose with a long screwdriver and got everything back together. So now I have Racetech emulators and Sonic springs. Also installed Galfer SS front brake lines and some EBC sintered pads. Can't wait for a nice day and some free time for a proper test ride!

02-14-2010, 06:58 AM	#4
Wistrick IR Newbie Join Date: Oct 2008 Location: TriCities Bikes: DL1000K3 Posts: 16 Trader Rating: 0% (0)	Re: Need help reassembling fork! Must be something in the water. I spent 1000 on my suspenders on the VFR at GP suspension, full front fork rework and penske double clicker in the rear...Does my heart good to see people spending money on this kinda mod!!!!!!!!!!!!! Dan

02-14-2010, 07:29 AM	#6
Wistrick IR Newbie Join Date: Oct 2008 Location: TriCities Bikes: DL1000K3 Posts: 16 Trader Rating: 0% (0)	Re: Need help reassembling fork! I paid $777.000 to my door!!!!!!! penske double clicker

02-14-2010, 07:36 AM	#7
virago_81 IR Addict Join Date: Feb 2007 Location: Plummer, ID Bikes: '06 SV650, '79 XL500S, '79 XR500R, '92 Trail Boss 250 Posts: 164 Trader Rating: 0% (0) View My Gallery	Re: Need help reassembling fork! Hmm. It is a shame to upgrade the fork and still have a mushy rear.

02-15-2010, 11:08 AM	#8
JiffyPark IR Administrator Join Date: Dec 2006 Location: Spokane Bikes: 07' Tiger, 03' DL1000 Posts: 693 Trader Rating: 0% (0) View My Gallery	Re: Need help reassembling fork! Does Bitubo make a unit for the SV? I had one on both a TLS and a TLR. Very affordable and have a good reputation at least in the TL community. I think I only paid around $450-$500 or so in a group buy. There is a member on my TL site who works for Traction Dynamics, he might be able to get me a deal on one if they make one. __________________ I like my skin so I wear gear...