I rebuilt the front forks late last year, here’s some pictures from the process!
First of course the bike is jacked up and front tire removed. These bikes have such a neat retro-future “speeder-bike” look without the front wheel/suspension:
Next the forks were removed, and I had to disassemble them. Honda made a specialty tool that would clamp onto the fork tube body and allow the spring-retaining nut at the top to be removed and then the spring pressure slowly released.
However that tool hasn’t been made forever and no way I was going to pay second hand prices for it. So off to the 3d printer we go…
The 3d printed piece works fundamentally the same as the Honda tool by clamping onto either side of the fork and using a couple threaded rods to retain the top and allow the spring to be compressed.
What was nuts was there was almost no fork oil left in either fork. They were both filthy! And of course I neglected to take any photos.
The OEM fork springs were swapped out for Progressive springs.
And then a hole was drilled/tapped into the fork cap to facilitate fork oil changes later on. You can drain the fork oil out of the bottom of the fork and then filling through the hole in the top by measuring very carefully lol.
The forks were reassembled with new seals, bushings and guides, then filled up with new fork oil of course.
