Replacing bent fork stanchion

[MC]

Not having much luck finding some used forks, so I'm wondering if it's a good idea to replace the stanchion, or are the internals likely to be bent as well?
https://i39.servimg.com/u/f39/15/13/82/47/bent10.jpg

The left fork looks straight to me, although you can see its had a bit of an impact, complete with some blue paint from the van I hit
https://i39.servimg.com/u/f39/15/13/82/47/straig10.jpg

Also I'm guessing a smashed headlight is an MOT failure, even though full/dipped beams still work?
https://i39.servimg.com/u/f39/15/13/82/47/headli10.jpg

Apart from that I think a new mudguard and brake pedal and it's good to go, whether it rides straight or not...
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Yamaha MT-03 '08 (crashed)
Honda XR-125L '04

[base]

With that kind of damage I would personally want to know if the head stock was still "true" before I started spending money on it.

[P.]

[Vincent]

Whip them off...remove the cap, and have a look. Springs should be OK, damper rod may need straightening out though....new bushes too maybe.
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Space Is Deep

[gavcarter]

Google fork straightening service and similar, you should be able to find some one local enough to do it for you, or give it a bash your self just for fun

[TUG]

I've bent some forks in my time, you will have damaged the damper rod and bent the top and or bottom yoke, depending how hard you hit the van the headstock bearings will be nicely fooked and possibly the front wheel bearings too.

When it comes to fixing a crashed bike, get the parts thoroughly inspected and replace if off, you might find some straight forks but if the headstock and clamps are fucked it will turn one way better than the other in a straight line.
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Haz ER-5, innit!

[Robby]

Pull them apart and see. The damper rod should be entirely enclosed by the fork lower, which looks fine. The bent bit only has the spring in it, and it doesn't look like enough of a bend in the fork to damage or compress the spring.

I wouldn't go with straightening on those forks, once you have a crease in the metal it's seriously weakened.

[gavcarter]

[Blue_SV650S]

Your yokes are going to be bent too ...
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The purpose of life is to fight maturity.

[TUG]

[mattsmith95]

Get new from WEMOTO, mind you it will NOT be cheap.

[nathan k]

[MC]

Thanks for the advice everyone. New forks are £400 each, a new stanchion is £110ish, and I'll probably attempt to do the job myself (even though the Haynes manual says it's a four spanner job ).

Quick question, the Haynes manual doesn't mention any special tools for reassembling the forks, yet the service manual does so do you really need them? I know some people say they use a bit of scaffold pole etc.
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Yamaha MT-03 '08 (crashed)
Honda XR-125L '04

[TUG]

[Vincent]

The only special tool I'm aware of is the one to hold the damper rod while undoing the bolt.....not strictly necessary tho.

There must be a pair of used forks somewhere.....you tried loads of breakers...and abroad?
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Space Is Deep

[TUG]

[Eddie Hitler]

Bend the other fork to the same spec as the damaged one, then it should ride fine.

[stinkwheel]

I'd take them apart BEFORE ordering new stanchions.

It's been a hell of an impact and you might find part of the lower has cracked too. I've had the spindle clamp crack through on a bike following a big frontal impact.

Worth checking the wheel is still true and uncracked and the wheel spindle isn't bent.
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“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[MC]

Some forks have come up for £220 (so the price of 2 new stanchions), what do you guys think? Also they're off a 2006 bike, but I don't think there were any changes to the MT-03 (mines a 2008 model).
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Yamaha MT-03 '08 (crashed)
Honda XR-125L '04

[Vincent]

I'd pay that as long as there's no pitting whatsoever in the swept area.
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Space Is Deep

[MC]

https://www.ebay.co.uk/itm/YAMAHA-MT03-MT-03-MT-03-FORKS-YEAR-2006-/161461356903?pt=UK_Motorcycle_Parts_13&hash=item2597d8c967

Looking again the forks for my model year are black
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Yamaha MT-03 '08 (crashed)
Honda XR-125L '04

[MC]

These black ones have come on eBay: https://www.ebay.co.uk/itm/Yamaha-MT03-660-2011-MT-03-MT-03-Front-Suspension-Forks-Read-Description-/181642689868?pt=UK_Motorcycle_Parts_13&hash=item2a4abf7d4c

They look a bit rough to me, thoughts?
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Yamaha MT-03 '08 (crashed)
Honda XR-125L '04

[Kickstart]

Hi

Not sure I would pay £175 for pitted forks. Wemoto have new pattern for tubes for £112 each

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[Vincent]

I wouldn't, for that much, I'd want near mint.
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Space Is Deep

[J.M.]

Don't restrict yourself to eBay. I found my replacement forks from somebody in the states that was breaking a bike, on a forum. Postage over here was a bit expensive, but the forks were good condition, and it wasn't able to find any in the UK at the time!
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2004 R1 & 2018 XSR900