Whats the best way to make fork spring preload spacers?

[snb73]

I need to make a 3/8 of an inch preload spacer. Unfortunately, I don't have access to a lathe. What would you guys suggest I use. I did a search and found some disscussion about using PVC pipe. Will this work?

Thanks, Steve.

 

[Trailryder42]

Sure, it's a popular alternative. Use the thickest walled stuff you can find(schedule 80?). I used a plastic pipe double female union and cut out of it what I needed(Two 3/4" pieces). Wall thickness on it was better and it's durability seemed like it would be better than regular PVC pipe.

 

[snb73]

A month ago, I had my suspension rebuilt. Heavier springs front and rear. Plus new bushings and seals up front. After the rebuild, I noticed a "pogo-stick" sound whenever I took the bike off the stand. When I removed the forks from the clamps if you shook them,you could hear the springs rattling inside the tubes.

I had a problem with bottoming on some medium jumps, even though the compression adjusters were screwed all the way in (hard). I knew this shouldn't be happening with the heavier springs. So I decided to take the caps off and found the oil was 1 inch below factory specs. I also found out why the springs were making noise. On full extension of the forks, like when on the stand, the springs had about 1/8 of an inch of freeplay (up and down movement) inside the tubes.

I replaced the fork oil and brought it up to the correct level. I went to Home Depot, Lowes, and even a hitch shop. I was looking for a washer with a 7/8 inch inner diameter and 1 3/8 inch outer diameter. I was hoping a hitch ball washer would work. No luck. I found the correct sized washers at our local True Value Hardware store. They were thick, so three washers gave me the 3/8 inch I needed.

Now the springs don't make any noise in the tubes. It was a simple fix that cost me $1.20 in parts and about 2 hours labor. It was my first time taking off the caps, so I was slow. I don't think I added enough of a spacer to effect spring rates, just enough to take up the slack in the tubes.

Hopefully the weather will cooperate and I can test out the mods.

Steve.

 

[TheJunkMan]

were do you put the spacers? in a conventional fork

 

[snb73]

I'm not sure, mine are "upside down"forks. I put the spacers (3 washers) in the fork cap. Here's an image of my forks.

http://houseofmotorcycles.bikebandit.com/partsbandit/showschematic.asp?dept_id=124540

I removed the caps from the forks and unscrewed them from the damper rods. Off came the circlip (28). I removed the spring seat (26) and the thrust washer. Together they make up about a 1/16 of an inch spacer. I installed the washers on the cap, reinstalled the circlip (28) and had my 3/8 - 1/2 spacers. On these particular fork caps, you can't have the spacer taller than 3/4 of an inch and still have the circlip (28) hold the washers onto the cap. You could make a taller spacer out of one piece of material, it's just that the circlip (28) won't be ablt to secure it to the fork caps.

Hope this helps, Steve.

 

[Pete Payne]

Also you could go to ypur local Cycle shop and check out the White Brothers catalog. They sell spacer in the suspension section, they have different sizes,and are cheap.