Planet Minis

Beerbatter · 02-16-2006, 08:27 AM

Hello again gang,

I just disassembled the front forks on my K4 and found that the bottoming bumpers that are attached to the aluminum end pieces that are in turn attached to the springs are shot and have to be replaced. It looks like the springs are wound onto the end pieces. The bumpers are inside the spring.

How in the world do I remove the end pieces from the wound spring so that I can replace the bumpers?

Thanks for any help on this.

dirtbkr188 · 02-16-2006, 02:33 PM

Clamp the squared edges of the end piece into a bench vise, and, using a hammer and drift punch, tap on the end of the spring to start backing it off. Work your way around for about a complete turn, and then you should be able to unthread it the rest of the way by hand. Before removing, take note of the position of the fork leg, and make sure then you thread the spring back in place, you get it to the same spot, otherwise the fork leg will be offset when you go to reinstall the front wheel and axle.

DAX MATT · 02-16-2006, 03:36 PM

I have been messing with my forks for the last week or so,and the easyest way I found to make sure the alignment is correct on rebuild is to look at the top cap the little peg that locates into the top of your forks it allways sits to the inside,you look down the fork from the top and line up the little peg to the centre of your axle hole and hey presto its all lined up on rebuild,much easyier than tryin fittin it then knockin it round a bit more when its out a bit

good luck matey doin it,its dead easy to do,on rebuild I put some fork grease on the springs and a bit on the bushes and it makes em work smoother

cheers matt

Beerbatter · 02-16-2006, 07:18 PM

Dirt,

Thanks man.
Why didn't I think of that. Now I understand the removal part.

When I put the spring back on though, how am I going to put enough torque on the spring going back the other way if I don't have the front edge of the spring to tap on?

dirtbkr188 · 02-16-2006, 09:33 PM

You'll be quite surprised at how easy it goes back on the end piece. You just have to put some real muscle into it at the very end.

Beerbatter · 02-17-2006, 04:25 AM

Sounds good. Thanks for your help.

02-16-2006, 08:27 AM	#1 (permalink)
Beerbatter PM Newbie Join Date: Feb 2005 Location: Sunny Florida Posts: 24	Fork Spring Question Hello again gang, I just disassembled the front forks on my K4 and found that the bottoming bumpers that are attached to the aluminum end pieces that are in turn attached to the springs are shot and have to be replaced. It looks like the springs are wound onto the end pieces. The bumpers are inside the spring. How in the world do I remove the end pieces from the wound spring so that I can replace the bumpers? Thanks for any help on this.

02-16-2006, 02:33 PM	#2 (permalink)
dirtbkr188 3rd Gear Member Join Date: May 2004 Location: New Jersey Posts: 2,973	Clamp the squared edges of the end piece into a bench vise, and, using a hammer and drift punch, tap on the end of the spring to start backing it off. Work your way around for about a complete turn, and then you should be able to unthread it the rest of the way by hand. Before removing, take note of the position of the fork leg, and make sure then you thread the spring back in place, you get it to the same spot, otherwise the fork leg will be offset when you go to reinstall the front wheel and axle.

02-16-2006, 03:36 PM	#3 (permalink)
DAX MATT PM Newbie Join Date: Nov 2005 Location: england Posts: 60	I have been messing with my forks for the last week or so,and the easyest way I found to make sure the alignment is correct on rebuild is to look at the top cap the little peg that locates into the top of your forks it allways sits to the inside,you look down the fork from the top and line up the little peg to the centre of your axle hole and hey presto its all lined up on rebuild,much easyier than tryin fittin it then knockin it round a bit more when its out a bit good luck matey doin it,its dead easy to do,on rebuild I put some fork grease on the springs and a bit on the bushes and it makes em work smoother cheers matt

02-16-2006, 07:18 PM	#4 (permalink)
Beerbatter PM Newbie Join Date: Feb 2005 Location: Sunny Florida Posts: 24	Dirt, Thanks man. Why didn't I think of that. Now I understand the removal part. When I put the spring back on though, how am I going to put enough torque on the spring going back the other way if I don't have the front edge of the spring to tap on?

02-16-2006, 09:33 PM	#5 (permalink)
dirtbkr188 3rd Gear Member Join Date: May 2004 Location: New Jersey Posts: 2,973	You'll be quite surprised at how easy it goes back on the end piece. You just have to put some real muscle into it at the very end.

02-17-2006, 04:25 AM	#6 (permalink)
Beerbatter PM Newbie Join Date: Feb 2005 Location: Sunny Florida Posts: 24	Sounds good. Thanks for your help.

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