Problem in Houston, front fork

htown16 · May 10, 2014

Had a clunk in the front end and fork didn't seem to act the way it should. Took the top nuts off the fork and on the left side the damper rod had completely unscrewed itself from the top nut and the retaining nut and washer below it had come completely off and were laying along side the rod. Fished those out with a magnet and got the damper to pull up in the fork but not enough room to put the thick washer and retaining nut on. Was wondering if I drain fork fluid and let suspension collapse using my hydraulic jack if the damper will come up enough to get the nuts on. Or will I have to pull the fork apart?

Nater_Potater · May 10, 2014

Re: Problem in Houston front fork

htown16 said:
Had a clunk in the front end and fork didn't seem to act the way it should. Took the top nuts off the fork and on the left side the damper rod had completely unscrewed itself from the top nut and the retaining nut and washer below it had come completely off and were laying along side the rod. Fished those out with a magnet and got the damper to pull up in the fork but not enough room to put the thick washer and retaining nut on. Was wondering if I drain fork fluid and let suspension collapse using my hydraulic jack if the damper will come up enough to get the nuts on. Or will I have to pull the fork apart?

You may have to remove the top nut from the right leg and push the front wheel up to get enough room to re-attach the nuts.

Roadrash · May 10, 2014

Re: Problem in Houston front fork

It's easier with no oil and on the bench for sure but it can be done on the bike full of oil as we'll. with the top nuts unscrewed from the tubes the forks will compress, exposing more spring to pull back. while keeping the rod from slipping down the tube, attach the washer and locknut. It takes all ten fingers and a few choice words but it can be done. Good luck

Chocko · May 11, 2014

I Had same problem , leave oil you can take front wheel off & push leg up or rest it on front wheel & push down on bike

john robert bould · May 11, 2014

The problem of nuts comming loose is the fact with "most" nut's the tread axis is out of square with the face , this twist's the nut over, i machine the face true on a mandril . Removing the zinc finnish is the down side ,with external use.
This out of squareness is common with "Modern" versions from you know where!

mschmitz57 · May 11, 2014

I've had this happen to me several times and I simply grab the damper rod using a flexible grabber tool with a claw on the end.
You can pick these up for a few bucks at the hardware store.
http://toolmonger.com/2006/07/29/flexible-grabber-tool/

Mark

Hobot · May 11, 2014

Been there done that too but the bad news in my case was the thick washer under damper tube had decayed either prior to loose clamp force or after wards. Best wishes on a Commando short cut success.

htown16 · May 12, 2014

Thanks for the replies. Looks like I got it. With the fork top nuts off I was able to collapse the forks enough to get room to work on it. I used a magnet on a rod to pull the damper up then used a pair of needle nosed vice grips clamped below the threaded part to hold it. The threads were a little buggered, so I ran a die over the rod and cleaned them up, along with a new nut and some blue loctite. While I was at it I changed the fork fluid. Refilling is a test of patience.
Everything seems to be forking okay.

Problem in Houston, front fork

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