How to seperate upper and lower fork legs - like 4357's ?
I have a 1989 KTM 125 MX with WP 4054 USD forks that need rebuilding . I have done WP 4357's by using a butane torch to seperate the upper and lower legs by expanding the DU bushings above the seal. Will this procedure work OK on the 4054 forks ?
- If you need clarification, ask it in the comment box above.
- Better answers use proper spelling and grammar.
- Provide details, support with references or personal experience.
Tell us some more! Your answer needs to include more details to help people.You can't post answers that contain an email address.Please enter a valid email address.The email address entered is already associated to an account.Login to postPlease use English characters only.
Tip: The max point reward for answering a question is 15.
drain the oil, taking care to hold the spring, remove the upper cap, drain the oil. remove the allen bolt from in the lower end of the fork, pull out on the inner leg forcefully. Do not attempt to dismantle the valving
Remove forks from bike, with each fork remove end cap and drain plug over a bucket drain oil from each fork reinstall drain plug on lower leg, replace oil thought top of the fork to spec, replace end caps and bleed oil from forks
Hi, i presume from your thread you have removed the bolt securing the damper to the leg at the axle end, and you are having a problem removing the stancion from the leg, normaly you will have to remove the fork dust seal from the top of the fork leg, you will then expose the main fork seal which will be secured inside the fork leg by a clip,you will need to remove this, as the bushing inside the fork. Is secured to the stancion underneath the fork seal the only way to separate this, once the seal clip is removed, fasten the lower leg in a vice, warning fasten in the axle area and not the tube area to save damage, once secure push the fork tube all the way to the bottom, then pull up sharpley, repaeting this action will give a hammer effect from the inside of the fork, when reasembling before fixing the damper unit replace the fork stanchion, bushing, washer and seal, holding the tube. Upermost will reduce the risk of damage while replacing the seal in the moving area
Having removed the forks, you will need to undo the lower damper bolt first, this is located on the recess inside the fork where. The spindle goes through, this will then alow you to remove the oil from the fork, and the leg will then be free from the stancion moving freely down, if the fork doesnot come apart, you will have to remove the retaining clip from the seal and pull the fork apart sliding the fork leg up the stancion and sharply pulling down on it to pull the seal out, repeat this till theseal comes out, (tip) undo the fork top nut while the forks are still fitted to the bike.
lower for legs there should be a drain bolt for each leg do one side at a time. Take the top fork cap off be careful the top cap is spring loaded get a pan to catch the oil,remove the drain bolt let it drain.reolace the drain bolt then you can add your new fork oil,check your owners manual for the proper amount and weight oil you need to replace, replace the fork cap. repeat steps on the other fork.
hi mate once the oil is drained you refill with 5w this is the standard oil and when you add the oil pump the dampers up and down until it stops squiling then you can fill it till it is 90mm/9cm from the top of the forks use a ruler and when it hit 9cm pump the forks then measure again if gotten lower top back up then screw the caps back on