bike forks

tiffy09 · L Plate Warrior Joined: 27 Dec 2007 Karma :

Hi, I'm new on here and need some desperate advice please!
I have a MBK XPower (exactly same as a Yamaha tzr) and i had an accident last year and need to replace the forks as they are bent. I have bought the new forks to go on and my Dad is doing the work with me. My Dad has worked on older bikes but my bike is modern and wondered if anyone had ever changed forks before on a yamaha or MBK? Or if you have any advice? I have fork oil and the right quantity. Any advice would be welcome!
Thanks!
Tiff Confused

Ichy · World Chat Champion Joined: 15 Jul 2005 Karma :

The best advice is to get a repair manual, do one at a time to make sure you don't mix bits up and change the seals at the same time.

They look just like plain ordinary forks so shouldn't be any different to what your dad is used to.

tiffy09 · L Plate Warrior Joined: 27 Dec 2007 Karma :

Thanks for the advice! Made a start after I posted my first thread and we have stopped now as we are stuck. We have taken one fork tube out and tried to take out the suspension but it won't budge and we are not sure how to either and do not want to damage the suspension. We are going to have to take it to my local mechanic where I bought the fork tubes from and see whether he can take the suspension thingy out; as we don't have a special tool which it looks like it needs or a technique that we don't know about. Sorry for rambling but I don't really know what I'm talking about!
Again, any advice welcome!
Thanks,
Tiff

Ichy · World Chat Champion Joined: 15 Jul 2005 Karma :

So you've removed the tube from the fork leg? This means you've already released the damper rod and released the seals which tends to be the hardest bit. It should more or less fall apart now.

This picture is from the TZR125 manual, look anything like yours?

tiffy09 · L Plate Warrior Joined: 27 Dec 2007 Karma :

thanks for the diagram; but my bike appears to be different. The large inner spring appears to be held in by a disc retained by a spring ring. Do you know if the inner part needs to be pressed out? We are struggling to get remove the inner parts to re-assemble the new tube.
Thanks again!
Tiff

Ichy · World Chat Champion Joined: 15 Jul 2005 Karma :

Photo's or a picture would be handy.

It sounds like you haven't released the cap holding the main spring in, should really be one of the earlier parts of the process.

Generally there are two ways of holding the spring in the leg, either a screw cap or a round disc held in place with a large circlip or similar.

Yours sounds like a circlip and disc. This needs to be compressed while the clip is removed then the pressure released slowly so no bits go flying all over the place. TBH it might be easier to partially reassemble the old tube back in to the yolks to hold things in place.

Search the net for fork seal change, there are thousands of them
https://www.teamcalamari.com/dox/tekfork.html
https://www.bluepoof.com/motorcycles/howto/svs_fork_oil/

tiffy09 · L Plate Warrior Joined: 27 Dec 2007 Karma :

Hi.
We have done it!!!! Woooohoooo! Lol. Just as I was writing the last thread my Dad had been messing around with the cap and the clip and realised how it was held together and voila!
Thank you so much for all the help and advice! The new tubes are on and bike is back together! Just got to sort out my battery problem!
Thanks again; you were a great help! Very Happy

Tiff