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Fork Rebuild


bowellsyboy
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Ive been doing my old bike up (99 gas gas txt) over the last year and is now running really well. The only problem i have with it is the forks seem lifeless, they work but there is just no spring in them at all. Is there anything you can do to rebuild them other than buying a new set of forks. Ive tryed different weight oils and adjusting the tops of the forks, which made absolutly no difference to the reaction of them. Im wondered if there broken? Anyone got any advice.

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Ive been doing my old bike up (99 gas gas txt) over the last year and is now running really well. The only problem i have with it is the forks seem lifeless, they work but there is just no spring in them at all. Is there anything you can do to rebuild them other than buying a new set of forks. Ive tryed different weight oils and adjusting the tops of the forks, which made absolutly no difference to the reaction of them. Im wondered if there broken? Anyone got any advice.

A couple of things to check:

1. Fork alignment (do the least expensive stuff first). Loosen all the fasteners except for the upper tripleclamp capscrews (axle, axle pinch bolts, lower tripleclamp capscrews and take off the fender brace). Push on the forks to "center" them and tighten the lower tripleclamp bolts. Again center the forks and tighten the axle. Center and tighten the axle pinch capscrews. Install the fork brace, and if the holes do not align with the mounts on the lower tube, file the holes so that the capscrews drop in. If this does not cure the problem, then do:

2. The mechanical condition of the forks. Make sure that the tubes are not bent by rolling them on a large flat surface, like a table top and seeing if there is a gap that appears between the tube and the surface (much better is two v-blocks and a dial indicator, but this will give you a rough measurement). Inspect the bushings, which are the grey Teflon coated collars on the bottom of the tubes and inside the inner part of the lower legs. If the coating is worn off at all, replace them. Make sure the rod in the center of the tubes (the cartridge rod) moves easily inside the cartridge.

Chances are that your forks are good, but are binding somewhere and they can be fixed, don't worry about needing new forks. If you're a little concerned about making a mistake, I'm sure you have a buddy that, with the promise of a pint, will be glad to look over your shoulder while you search for the solution.

I think the 99' has the three-piece lower fork leg, but they are basically the same as the later model GasGas forks and work well when properly adjusted. I don't know your weight, but some added preload may also help.

Jon

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