Fork disassemble advice...

I'm taking the forks apart to have the fork sliders powder coated. I will for certain replace the seals and oil when I reassemble but was wondering what parts get or could most likely get damaged and should have spares on hand for? Thanks in advance!

 

The bolts that hold the slider to the damping rod and the accompanying crush washers. Sometimes you have to drill out these, so would be good to have on hand. Although determined by age and use, the inner bushings might be something to consider as well.

 

I agree with OOTV on the above. If you are disassembling the fork for a refresh then replacing the bushings would make sense.

 

If you have the dough and already have them apart, get in touch with Jamie Daugherty for an upgrade on those forks.

That's my plan anyways.

 

Cadbury and OOTV....right since I don't want to go back in the sooner than I have to, I should do it right for a few pennies more.

Jeff... Have some extra dough for ol' Boosh?!?? ;^)

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Prime Minister Photo Op might have some dough to give you ... he took some of mine away ... lolzzz

 

Hahahahaha

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Bushings are $16 a side, seals $20 a side.

I've never wrecked a damper bolt (yet), but if you have access use an impact driver to break them loose before disassembling anything else. Also break the fork cap loose when still in the bike. If the fork has never been apart then the copper washers should be fine to re-use (I've done this many times).

A piece of PVC pipe 50mm diameter about 600mm long is perfect to use as a seal driver, or slip new seal on, then old seal on top and drive on the old seal. Put seals in the right way up (DAMHIK).

 

Hey thanks... Is that OEM pricing in USD?

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Yes indeed, US$ from Partzilla. I now order all my OEM stuff from them even though they are far, far away, still quicker and cheaper than the local dealer.

http://www.partzilla.com/parts/search/Honda/Motorcycle/1999/VFR800FI+A/FRONT+FORK/parts.html

 

Do i have to take all the crap off the handle bars or can I just lift them off whole?

 

Place a nice thick towel or moving blanket over the tank and l/r front fairings and just pull the clip-ons off with everything attached, and lay them on the towel/blanket.

 

You can hang towels on either side of the bike and let the controls rest there. All the stuff they said above and be sure to give your extended allen socket a good rap with a hammer before you attempt to remove those damper bolts on the bottom of the fork legs, bent key allen keys dont apply here.

 

Oh good....I thought I could get away with it. The manual would have you take everything off. Thanks!

 

Fork removal is actually pretty easy; some traps for young players on the VFR:
Loosen the fork cap bolt before you take the forks out of the bike
There's a thin circlip above the handlebar on the fork tube that has to come out before the forks will slip out; lift the fork tube up slightly to get at it
Take off the zip ties that hold the cables to the legs
Break loose the damper rod bolt with the fork still assembled (spring preload helps stop the internals spinning); use an impact driver if you can
Back off the preload before unscrewing the fork cap.
Be prepared for a lot of mess from oil drips!

 

+1 On ALL the above!

 

Yes...easy once you do it!

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So there are 2 small needle bearings in the right fork lower ... P/N 91101-KG8-003 and my Honda dealer wants $34CDN +tax ea. Partzilla $29CDN ea. + shipping. Could these be sourced anywhere else?

 

Bearings can be sourced elsewhere but you need to know how to read and decipher the numbers. I'll go check for the link that shows how to do this...

 

Explanation of bearing #'s ...

http://www.engineerstudent.co.uk/bearing_numbers_explained.html