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Sir m40man
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D9 Forks - seal replacement
« Thread Started on Nov 1, 2009, 2:06pm »
Greetings, fellow perusers of the Tech Info' & Modifications area of YDC! (& anyone else, who happens along because they are using the "View the 50 most recent posts of this forum"!)

I need to know what size nut I need to weld onto the end of my extension, in order to hold the internals whilst I undo the 8mm hex on the underneath of the fork leg, so that I can separate fork leg & tube.

Broom handle is in splinters now, so is it time for a proper job! Can you tell me if its a 23mm, 24mm, or summat else please?

Ta,

Martin.

(Edit: I actually MUST separate these parts, so no tips on seal replacement without separation please. I have to swap over a bent fork tube with a good one whilst replacing the seal.)
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Re: D9 Forks - seal replacement
« Reply #1 on Nov 1, 2009, 4:24pm »
Hi Martin,this might be a bit late for you but i think its 24mm you need,


Ray
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Re: D9 Forks - seal replacement
« Reply #2 on Nov 1, 2009, 4:50pm »

Nov 1, 2009, 4:24pm, chunk166 wrote:
Hi Martin,this might be a bit late for you but i think its 24mm you need,
Ray
Hi Ray, a 24mm certainly fits on D6 forks. Alas, the D9 ones appear to need a tad bigger. I know this now 'cos since first posting I bought a couple of car tow-balls bolts (24mm) & locking them together & sticking 'em on the end of my 1/2inch socket extensions via my 24mm socket, it tries to grip but doesn't locate soundly. Even so, I have now managed to separate one of the forks. Just need to do the other one (with a good straight slider) & that one's being a 'bugger! Last assembled by some Neanderthal >:(.

..... I've quit for the day now, 'cos tea & cakes was on offer & you have to get in quick around these parts :o 8-).
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Re: D9 Forks - seal replacement
« Reply #3 on Nov 1, 2009, 5:05pm »
Don't forget to put the fork seals in the right way up ::)
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Re: D9 Forks - seal replacement
« Reply #4 on Nov 1, 2009, 5:13pm »

Nov 1, 2009, 4:50pm, Sir m40man wrote:

Nov 1, 2009, 4:24pm, chunk166 wrote:
Hi Martin,this might be a bit late for you but i think its 24mm you need,
Ray
Hi Ray, a 24mm certainly fits on D6 forks. Alas, the D9 ones appear to need a tad bigger. I know this now 'cos since first posting I bought a couple of car tow-balls bolts (24mm) & locking them together & sticking 'em on the end of my 1/2inch socket extensions via my 24mm socket, it tries to grip but doesn't locate soundly. Even so, I have now managed to separate one of the forks. Just need to do the other one (with a good straight slider) & that one's being a 'bugger! Last assembled by some Neanderthal >:(.

..... I've quit for the day now, 'cos tea & cakes was on offer & you have to get in quick around these parts :o 8-).



I thought it was 27mm ;)
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Re: D9 Forks - seal replacement
« Reply #5 on Nov 1, 2009, 5:52pm »

Nov 1, 2009, 5:05pm, cam7777 wrote:
Don't forget to put the fork seals in the right way up ::)
You've never fitted original Honda CB650 fork seals, have you :P? Well, you'll be pleased to know this D9 is getting cheapy pattern seals, so it won't ever confuse any future purchaser, even if they live in Pikey Peterborough :-*.

Nov 1, 2009, 5:13pm, HRH Penfold wrote:
I thought it was 27mm ;)

Cheers Ian ................... so ............... anyone got a 27mm wotsit I can borrow ?
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Re: D9 Forks - seal replacement
« Reply #6 on Nov 2, 2009, 12:45pm »
I used a tube spanner dead cheap from a plumbers merchant and it just happened to fit.
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Re: D9 Forks - seal replacement
« Reply #7 on Nov 2, 2009, 2:09pm »

Nov 1, 2009, 5:52pm, Sir m40man wrote:

Nov 1, 2009, 5:05pm, cam7777 wrote:
Don't forget to put the fork seals in the right way up ::)
You've never fitted original Honda CB650 fork seals, have you :P? Well, you'll be pleased to know this D9 is getting cheapy pattern seals, so it won't ever confuse any future purchaser, even if they live in Pikey Peterborough :-*.

Nov 1, 2009, 5:13pm, HRH Penfold wrote:
I thought it was 27mm ;)

Cheers Ian ................... so ............... anyone got a 27mm wotsit I can borrow ?



You could make one using a M18 bolt welded to a bit of pipe ;)
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Sir m40man
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Re: D9 Forks - seal replacement
« Reply #8 on Nov 2, 2009, 6:48pm »

Nov 2, 2009, 2:09pm, HRH Penfold wrote:
You could make one using a M18 bolt welded to a bit of pipe ;)
Righto' - so a bolt from this:
[image]

......... welded onto which bit of this?:

[image]

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Re: D9 Forks - seal replacement
« Reply #9 on Nov 2, 2009, 7:19pm »

Nov 2, 2009, 6:48pm, Sir m40man wrote:
[
[image]




D'ya get them free with the fazer then? ;D
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Re: D9 Forks - seal replacement
« Reply #10 on Nov 8, 2009, 5:42pm »
Right - A progress report & a request for help!

One or two of you will know that JTB had his prang on his D9, & that's why I've been seeking advice on a D9 fork seal replacement.

I hope John doesn't mind me posting - but we need help!

Today we fitted the replacement fork leg & wheel.

Got the straight slider into the right (left!) leg so now instead of Johnthebowman's bike looking like this:
[image]

It looks like this:
[image]

We have a replacement front mudguard courtesy of Ray:
[image]

.... and with the replacement front wheel & discs (kindly donated by TJ900 / TEEJAYEXC/Trev whatever he calls himself today!), John can pose like this:
[image]

But on closer inspection all is still not well. In the pic above, John is holding the bars straight, but the wheel is decidedly not pointing ahead!

We loosened the bottom clamps on both legs & straightened it up, using a nearby kerb. But whilst it straightens, it flexes back & obviously summat is bent. Lower fork clamps, we suspect.

Here's what the bars look like, with John keeping the front wheel pointing straight ahead:
[image]

so ...... tips, advice, offers of help with whatever we should do next please :-/.
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Re: D9 Forks - seal replacement
« Reply #11 on Nov 8, 2009, 6:13pm »
Couple of thoughts,

Is the Fork you didn't replace OK ? The lower Fork clamps line up with the top clamps ? You can check this with a square and it might also tell you if one of the clamps is bent. I had exactly this problem with one of Jr's bikes after a front ender, the fork clamps were out of alignment.

Did you try fitting the wheel spindle without the wheel this also gives you an idea of where the alignment is skewed.

Hope you can figure it out.
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Re: D9 Forks - seal replacement
« Reply #12 on Nov 8, 2009, 6:19pm »
Course I don't mind you posting Martin :)

Y.D.C. Members can now see for themselves just how clear of junk my garage is and how well the spring on the door works ;) ;D ;D

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Re: D9 Forks - seal replacement
« Reply #13 on Nov 8, 2009, 6:20pm »
Garage looks pretty standard to me. ;)
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Re: D9 Forks - seal replacement
« Reply #14 on Nov 8, 2009, 6:24pm »
Bev, thanks for your post the other fork seems straight but to cause this twist would it not have to be bent forwards! Which confused both Martin and me.
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Re: D9 Forks - seal replacement
« Reply #15 on Nov 8, 2009, 6:36pm »
JTB, Don't know what the impact was like but if a twist was put on the front end then that fork could well bend forward. It's amazing how metal acts under impact.

Best guess would still be clamp alignment though.
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Re: D9 Forks - seal replacement
« Reply #16 on Nov 8, 2009, 6:40pm »

Nov 8, 2009, 6:13pm, Bev wrote:
.... I had exactly this problem with one of Jr's bikes after a front ender, the fork clamps were out of alignment.
We were thinking along this line. The left leg is certainly further back than the right one, by the time it approaches the end of it's length. Wheel was therefore hard to line-up. Kinda hoped it would all pull together nicely :-/. We know the left fork is straight & the right looks straight & as John says, it is unlikely the fork itself would have bent forwards. So the bottom clamp / yolk thing - repairable, or do we need a replacement? (Looks like it's cast, so I'd have thought trying to straighten it would be risking it fracturing??)
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Re: D9 Forks - seal replacement
« Reply #17 on Nov 8, 2009, 6:48pm »

Nov 8, 2009, 6:13pm, Bev wrote:
Couple of thoughts,

Is the Fork you didn't replace OK ? The lower Fork clamps line up with the top clamps ? You can check this with a square and it might also tell you if one of the clamps is bent. I had exactly this problem with one of Jr's bikes after a front ender, the fork clamps were out of alignment.

Did you try fitting the wheel spindle without the wheel this also gives you an idea of where the alignment is skewed.

Hope you can figure it out.


I think the bottoms slightly twisted, so your having to move the top out to line it up, :-/
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Re: D9 Forks - seal replacement
« Reply #18 on Nov 8, 2009, 8:51pm »
OK - so it seems we're looking for a lower yoke - We'll see what Ebay has.

............ John just rang me to complain that I hadn't posted the pic of him riding the bike in the grounds of his estate, so here he is:
[image]
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Re: D9 Forks - seal replacement
« Reply #19 on Nov 8, 2009, 10:00pm »
From speaking to John earlier it certainly sounds like a twisted yoke.No way to repair the casting, TBH, so onto the bay it is.Might even find one with a decent bearing on the stem to save faffing about.
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Re: D9 Forks - seal replacement
« Reply #20 on Nov 8, 2009, 10:08pm »
http://shop.ebay.co.uk/?_from=R40&_trksi....-All-Categories

;)
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Re: D9 Forks - seal replacement
« Reply #21 on Nov 9, 2009, 1:03am »
On my old XS which had a low speed off but the car that hit it was moving right to left the forks were bent & when reassembled although frame & forks were straight the bit where the forks clamped was bent & that was cast so I thought it would have broken not bent but it bent it did.

Hope this helps

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Re: D9 Forks - seal replacement
« Reply #22 on Nov 9, 2009, 2:31am »
Yes it does help Neil. Martin and I were coming to that conclusion and your post here plus Bev and HRH Penfolds posts have helped us come to the conclusion.

That I need a new bottom yoke.

Trev you sir are a star :) and not for the first time.
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Re: D9 Forks - seal replacement
« Reply #23 on Nov 9, 2009, 10:45pm »
Courtesy of Bobh, lower triple clamp [1] complete with headstock bearings are now in my possession :).


[1] Complete with unmolested 'stops' John - so you won't have the impressive turning circle you currently enjoy ;).
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Re: D9 Forks - seal replacement
« Reply #24 on Nov 10, 2009, 12:18am »
Martin that's wonderful :)

Must admit to being a bit frightened of ebay. :o ;D
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Re: D9 Forks - seal replacement
« Reply #25 on Nov 10, 2009, 8:40pm »
Lower yoke & gubbins all cleaned-up, re-greased, & ready to go .... in very nice condition, so thanks again, Bobh :):

[image]
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Re: D9 Forks - seal replacement
« Reply #26 on Nov 10, 2009, 8:50pm »

Nov 10, 2009, 8:40pm, Sir m40man wrote:

[image]


:o

A laptop in yer shed! Confirmation, (if any was really needed), that Southerners are all posh gits :-*
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Re: D9 Forks - seal replacement
« Reply #27 on Nov 10, 2009, 9:03pm »

Nov 10, 2009, 8:50pm, teejayexc wrote:
:o
A laptop in yer shed! Confirmation, (if any was really needed), that Southerners are all posh gits :-*
Surely one must have access to an on-line parts fiche 8-).

Do you take a photo of your laptop screen, take the old 120 film out of your Box Brownie along to your nearest Boots for processing, go back in a few days to collect & then arrange the photos on your garage wall using drawing pins :P ?
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Re: D9 Forks - seal replacement
« Reply #28 on Nov 10, 2009, 9:13pm »

Nov 10, 2009, 9:03pm, Sir m40man wrote:
Surely one must have access to an on-line parts fiche 8-).

Do you take a photo of your laptop screen, take the old 120 film out of your Box Brownie along to your nearest Boots for processing, go back in a few days to collect & then arrange the photos on your garage wall using drawing pins :P ?



How did you know? 8-)

Though looking under the tank and seat of the Striple t'other day, it seems a laptop may be on the shopping list for servicing requirements :-/
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Re: D9 Forks - seal replacement
« Reply #29 on Nov 10, 2009, 11:32pm »
Thanx Bobh, :)

Its me that should be thanking you rather than Martin ;)

Thanks again Martin and thanx for cleaning it up :)

Looks like a good part. Roll on the day that computers have materializes connected to them rather than printers ;D

I wonder if it can be fitted without removing the fairing
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