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Any tips on installing fork travel limiters? Getting ready to start my big wheel kit.


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Lets see what I can remember here....

Use the service manual as a guide. It helps on the disassembly and reassembly. Mine was a 2013 and it was a little bit different than what the manual said. I guess they changed up some from 2011.

Air/impact tools are a must.

Start by removing the big nut on top of the fork. Hold the body with your hand and use an impact gun to remove cap. Turn it upside down to remove some of the oil.

Next I used a small pair of vise grips to hold the inner rod while I used the impact gun to remove the nut on top of the rod. Use caution because there is some pressure on the springs and they will want to pop out once the nut is removed.

Remove the two springs and all the spacers. Move the inner rod up and down to help get the rest of the oil out. It gets messy.

Make sure you have a long set of hex head sockets to remove the cartridge assembly. I had to rig a tool up because I didnt have a long set. I think it takes a 6 or 8mm. From the bottom of the fork tube, remove the bolt that is holding the cartridge assembly in. Again, use a impact gun because everything will turn while you try to remove this bolt.

Now you can pull the cartridge assembly out. The limiting spacer goes on the bottom of the rod.

Put everything back in the fork tube following the guidelines in the manual to work the fork oil into the fork and get all the air out. I put a half a quart in each tube.

Now is the fun part...compressing the springs by hand.

I had to get my fiance to help me because I really needed an extra hand. After several hours of fighting the first one, this is the best way I came up with. I know it sounds retarded but it worked. Tie a piece of fishing line around the inner rod and run it up through the middle of the top spring. This helps to hold the up because it drops back down on its on. I then took a pair of needle nose vise grips and put it through one of the top coils of the springs. (You will see where to put them when you start working with the spring)

Press down on the spring with every bit of energy you have to get it to compress, while holding up on the fishing line. When the top of the inner rod is past the spring, clamp down on the needle nose vise grips. This holds the spring and rod in place. Now start the nut on the inner rod and tighten down.

Finish by putting the top cap back on the fork tube.

Now go drink you several beers to relieve some frustration.

Dont worry, once you get through with the first one, the second one is a piece of cake.
 

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Does anyone by chance remember what size Allen socket for the front tire? Any other oddball tools needed for the front assembly?


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If you are referring to the axle size it is 16mm hex or 5/8ths. The I normally avoid swapping SAE for Metric, but the 5/8 is tight (and a lot easier to find)
 

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My hands were too messy to take pictures along the way. I used the parts diagram as a reference. The service manual also has a pretty decent tutorial that I used to install mine. My local shop was Hot Vic and they wanted me to leave my forks up there several weeks before they would get around to it. I said hell no.
 
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