Stephen Baker <[email hidden]> wrote in message
"]news:[email hidden]...
Quoted message said:Dang, SR, I'd love to help you out, but I know absolutely nothing about
the
Quoted message said:subject! ;-(
Quoted message said:Good Luck, though.....
I needed it too:
Took wheel off, removed pads from calliper, took top caps, springs and oil out of forks this
morning, ready for the job at lunch time....
Lunch time:
I got the 15 mm socket, and undid the retaining nut from inside (recessed by a couple of inches) one
of the lowers - no worries. Couldn't find the other one, because there's this little rebound adjust
know on the other side.......
Finally, after much careful thought and deliberation (pissing about), I realised the knob 'pulls
off', to reveal the shaft it attaches to, and the other nut, again, set inside the tube. This nut
has the shaft coming out the centre of it, 3 or 4 inches long.
'There ain't no way I'm getting that thing off with a 15 mm socket', thunk I to meself, and of
course, I was right.
So, off to search for an extra long 15mm 'box key' jobby......no such
Right, I gets meself an old 15mm socket, and a section of 3-4 mm mild steel rod, and I weld the
buggers to each other, then bend the rod into a right angle part way up. Now, this little beastie
does the job, and I remove the lowers.
Using a big screwdriver and a big hammer, I gently prise ('[censored]'😉 the dust seals, then the oil seals
(after using needle nose pliers to gently remove the retaining clips), out of their little homes,
and clean inside the tubes.
Then, I remove the two big washers/spacers from on top of the bushings/sleeves, and using a metal
rod through the holes in the bottoms of the sliders, I carefully push out the old bushings/sleeves -
new ones go in easy. Drop washers back on top.
Get new oil seals, cover 'em in fork oil, and gently press ('[censored]'😉 the oil seals in with a big
hammer and a section of steel tubing the right diameter. They go in no problems, as does the first
of the dust seals (for these, I used the big hammer and the old dust seals to seat them). Second
dust seal goes in '[censored]-eyed', and I can't get it out to put it back in flat without screwing it up,
so, I just have to keep encouraging ('twatting'😉 it into place. Finally, it's more or less seated,
albeit in less than prime condition (sealing parts are OK though).
I'm now ready to re-assemble upper and lower parts, when I notice a little 'O' ring on the floor. I
find out it's fallen from the bottom of one of the sliders, around the bolt hole - other is still in
place. I put this 'O' ring on the nut, and start putting stuff together.
A bit of fiddling with the nuts (eh!) because they don't want to catch their threads, and I've got
everything back together.
Put in oil, put in springs, put on one top cap....whoops! Forgot to put the little tube and big
washer in there for the pre-load to act on, back off with it, bits in, back on with it, back on with
the other, re-fit brake pads, drop wheel in, tighten QR, set pre-load, set rebound, push bike
outside. Check, yup! Everything feels right, good as can be.
Come back in to clean up, I'm only 15 minutes over due to finish my lunch, so not too much of a rush
eh? Heh, right, get nearly everything cleaned up, all tools back in place and stuff, when what
should I find on the floor?
Gonna have to see if one of the fork legs is leaking from underneath in a bit - have to strip 'em
down again, maybe tonight to put that little [censored] back in place......
Anyhow, now that I know what tools I need, and what to do/look out for, I can honestly say, the job
is a piece of [censored]. First time blind attempt though? An hour and a half isn't enough time to do it
unhurriedly, and smoothly get it right.
Anyone comes to do this job and has any questions, just give me a shout! Heheheheh.......
Shaun aRe
P.s. - Forks in question are, specifically, '02 Marzocchi MXR coil/oil, 100mm SSVF thingies.
