lower fork leg casting

Taffy said:

try and undo the compression stack out the bottom of the leg and do it while it's high in the vice. lay on bench and then tip fork up to catch the oil.

take off duct cap and internal circlip.

now, holding the two legs in each handthrust away each part: slap, slap, slap and the inner and outer legs will split,

get ready for lots of oil!

stick it in the new leg and if you want just add 480cc through the bottom eye of the leg to finish. otherwise you'll need to get the air height right as per the doc.

regards

Taffy

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nizzo said:

Sparks,

I've ran into this once before. They are threaded together and WP has used tons of loctite. You'll need a fair bit of heat to melt the loctite. I had to use a cutting torch to get enough heat (don't melt the aluminum!!). Basically heat the aluminum lower until you're confident the loctite is melted, then clamp the lower in a vice, then use a strap type automotive oil filter wrench to unscrew the steel tube or stick a long punch in the holes at the top of the tube. It will take a fair bit of effort and you may need a buddy to help, cause the aluminum will shed the heat very fast and the loctite will set back up pretty quickly. We had to keep the heat on the lower while we were unscrewing the tube.

To reassemble, be sure to clean up the threads very well. Then use lots of loctite (I used red because this is essentially a permanent joint). You don't want the lower coming loose.

Take care,
nizzo

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sparks said:

nizzo said:

Sparks,

I've ran into this once before. They are threaded together and WP has used tons of loctite. You'll need a fair bit of heat to melt the loctite. I had to use a cutting torch to get enough heat (don't melt the aluminum!!). Basically heat the aluminum lower until you're confident the loctite is melted, then clamp the lower in a vice, then use a strap type automotive oil filter wrench to unscrew the steel tube or stick a long punch in the holes at the top of the tube. It will take a fair bit of effort and you may need a buddy to help, cause the aluminum will shed the heat very fast and the loctite will set back up pretty quickly. We had to keep the heat on the lower while we were unscrewing the tube.

To reassemble, be sure to clean up the threads very well. Then use lots of loctite (I used red because this is essentially a permanent joint). You don't want the lower coming loose.

Take care,
nizzo

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Hi Nizzo,

Many thanks for the good explanation, will give it a try today, they say the alluminum casting is very expensive to from WP, on further inspection when I was stipping the fork leg the damper tube also is slightly damaged due to the spring squashing up against it but the damper rod is ok, this will also have to be replaced.

On reaasembly I have read some where that you leave out the aluminum tube and the centre bushing, the bike is an 04, if you look at the part manual for 05 these two parts are nolonger there.

Regards

Sparks.

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