SuzukiSavage.com - Fork re-teardown

barry68v10

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Fork re-teardown
12/08/07 at 13:59:14

Well, I've torn the forks down again and found a combination of problems...

Worn parts contributed to most of the lack of dampening. They were worn unevenly, I believe, due to incorrect assembly at the dealership as I've stated previously.

However, at least some of the problem was the #10 weight oil (synthetic ATF) that I used.

Yes Greg, I agree that 10# is too thin for me in the Savage, you were right. Let the gloating commence Tongue

I will say that the ride was more comfortable. Grin

On another note, I've tried to figure out why things went south "all at once." The only thing I can figure is the dampening ports may have been partially clogged and the use of a thinner full synthetic oil with lots of detergents cleaned it out in conjunction with enough extra wear on parts to allow fluid bypass...I did notice that there was still a lot of metal in the oil despite the fact that I drained the forks initially for several hours.

In the interim, I've reassembled the forks with 10-40 motor oil until my parts arrive. A quick test ride seemed to indicate much stiffer response, about equal or a little softer than I seem to remember before the failure. Undecided

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petc0ck mod, white spacer removed, 150 main jet, 12.5" shocks, 16" turnout muff, oil cooler mod, chain conversion, Tkat brace, external fuel filter, fuel screen removed...

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Savage_Greg

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Re: Fork re-teardown
Reply #1 - 12/09/07 at 06:40:28

No gloating here. After all, I didn't engineer the forks or the oil. I simply follow the manufacturer's recommendations Tongue

Since the forks "went south" all at once, could it be possible that you have is some new wear on the parts? Certainly you can't get all the old oil out without a teardown, but if the other oil didn't lubricate correctly maybe you have new damage. What is worn? The bushings?

...and the story continues...

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azjay Serious Thumper Offline aridzona... its a dry heat Posts: 816 Gender:	Re: Fork re-teardown Reply #2 - 12/09/07 at 06:41:13 appreciate the extra experience you're getting, you've graduated from from fork builder to fork expert
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Fork re-teardown Reply #3 - 12/09/07 at 07:50:37 ...an expert forker
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Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: Fork re-teardown Reply #4 - 12/09/07 at 08:10:43 verslagen1 wrote on 12/31/69 at 16:00:12: ...an expert forker Either that, or he's been forked
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Dr_Jim Ex Member	Re: Fork re-teardown Reply #5 - 12/09/07 at 10:40:16 -
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Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: Fork re-teardown Reply #6 - 12/09/07 at 10:54:49 Well, I guess that's the end of this topic... 8)
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barry68v10

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Re: Fork re-teardown
Reply #7 - 12/09/07 at 15:13:41

Savage_Greg wrote on 12/31/69 at 16:00:12:

No gloating here. After all, I didn't engineer the forks or the oil. I simply follow the manufacturer's recommendations Tongue

Since the forks "went south" all at once, could it be possible that you have is some new wear on the parts? Certainly you can't get all the old oil out without a teardown, but if the other oil didn't lubricate correctly maybe you have new damage. What is worn? The bushings?

...and the story continues...

I guess anything is possible but I'd be extremely skeptical that the new oil didn't lubricate correctly.

For what is worn, I gotta break out the book and try to figure out the proper names for all these widgets...

Let's see, the dust seals were allowing water in, and the stopper rings were rusted. The springs were way in tolerance...so no problem there. The rest of the parts I'll give more detail when I have a chance to compare them to their new counterparts where I think differences will be more glaring than in my darkish garage. I suspect the damper rod and piston ring, fork tube bushings and oil seal will need to be replaced but hard go gauge just how bad they are without a gauge. Grin

Hey Greg, how 'bout I just ship the forks to you, you can tear 'em down and take pictures for the site, then reassemble them and ship 'em back? Grin

I'll give an update when I can get the new parts and tear 'em back down and compare stuff...one thing I didn't check is the tube. The Cymers says if the tubes are scarred you must replace them. Makes sense, but I might should've checked that! Roll Eyes

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petc0ck mod, white spacer removed, 150 main jet, 12.5" shocks, 16" turnout muff, oil cooler mod, chain conversion, Tkat brace, external fuel filter, fuel screen removed...

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Savage_Greg

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Re: Fork re-teardown
Reply #8 - 12/09/07 at 15:16:47

barry68v10 wrote on 12/31/69 at 16:00:12:

I guess anything is possible but I'd be extremely skeptical that the new oil didn't lubricate correctly.

For what is worn, I gotta break out the book and try to figure out the proper names for all these widgets...

Let's see, the dust seals were allowing water in, and the stopper rings were rusted. The springs were way in tolerance...so no problem there. The rest of the parts I'll give more detail when I have a chance to compare them to their new counterparts where I think differences will be more glaring than in my darkish garage. I suspect the damper rod and piston ring, fork tube bushings and oil seal will need to be replaced but hard go gauge just how bad they are without a gauge. Grin

Hey Greg, how 'bout I just ship the forks to you, you can tear 'em down and take pictures for the site, then reassemble them and ship 'em back? Grin

I'll give an update when I can get the new parts and tear 'em back down and compare stuff...one thing I didn't check is the tube. The Cymers says if the tubes are scarred you must replace them. Makes sense, but I might should've checked that! Roll Eyes

I bet that 90W gear lube won't leak too easily Tongue

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barry68v10 Serious Thumper Offline Posts: 955 Maryland Gender:	Re: Fork re-teardown Reply #9 - 12/09/07 at 15:21:11 Savage_Greg wrote on 12/31/69 at 16:00:12: I bet that 90W gear lube won't leak too easily And don't think I didn't consider that either Got a quart of the stuff sitting in the garage
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Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: Fork re-teardown Reply #10 - 12/10/07 at 04:53:28 barry68v10 wrote on 12/31/69 at 16:00:12: And don't think I didn't consider that either Got a quart of the stuff sitting in the garage Be kinda like a rigid front end...
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T Mack 1 - FSO Serious Thumper Alliance Member Offline sold 2001 LS650 for a 1986 XLH1100 Posts: 2919 Emmaus,Pa Gender:	Re: Fork re-teardown Reply #11 - 12/10/07 at 05:40:45 Savage_Greg wrote on 12/31/69 at 16:00:12: Be kinda like a rigid front end... My shoulders hurt just thinking about that one.
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Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: Fork re-teardown Reply #12 - 12/16/07 at 04:50:47 Any progress on the forks yet?
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barry68v10 Serious Thumper Offline Posts: 955 Maryland Gender:	Re: Fork re-teardown Reply #13 - 12/19/07 at 17:02:45 Thanks for asking Greg. The project has been postponed due to "unforseen life events." It may be a couple months now... I'll update you when the Savage makes it back to the top of the "to do" list...
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Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: Fork re-teardown Reply #14 - 12/20/07 at 05:15:06 Dam. It happens and I hate it
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