2003 Fork Rebuild Parts?

[audiowize]

So I've got a front end clunk on my 2003 when coming to a hard stop or going over a reasonable lump in the road. I plan to both re-torque the steering head bearing and freshen up the front forks as soon as possible. With low mileage on the bike (27,000 or so), I'm not planning to replace the springs.

https://www.mrcycles.com/oemparts/a/yam/50044a68f8700209bc79081a/front-fork

On this diagram, it looks like I need two seal kits, two metal slide 1, and two metal slide 2? (And oil of course)

Do I need anything else to complete the job?

 

[Bustanut joker]

Nope.. Just somebody to do the work while ya drink beer.

At least that's how I do it here.

 

[MCRIDER007]

Yes....you need new springs. The OEM 03 springs were even softer than the the 04/05 springs. There isn't any reason to change bushing and seals with such low mileage unless the seals are leaking.

 

[Bustanut joker]

I dunno.. I've seen bushings with less than 20 k on 'em look pretty toasted.

Plus yer going to trash the upper getting the forks apart, and I highly suggest he does this to fully clear the forks of the nasty oil.

24k and 11 years is too long on the oil.

 

[odot]

.....that's too much on the oil? dang......I'm on 78 grand and nine years....guess I'm good.

....wait....I'm out of oil....it stopped leaking about two months ago..........

 

[Bustanut joker]

^^^ Wouldja lookit what crawled outa the woodwork? Hole E fukin ****!



Yer good to go dik face. Whale oil is a permanent lubricant.. Even when it's gone.

 

[audiowize]

Yes....you need new springs. The OEM 03 springs were even softer than the the 04/05 springs. There isn't any reason to change bushing and seals with such low mileage unless the seals are leaking.

That's good information, and something that I was wondering about. 04/05 springs aren't all that hard to come by.

My rationale for tearing apart the forks was that I don't want to go back in there if the clunk persists, but my gut tells me that this is an issue in the steering head bearing.

 

[RadioHowie]

My rationale for tearing apart the forks was that I don't want to go back in there if the clunk persists, but my gut tells me that this is an issue in the steering head bearing.

I wouldn't bet the farm on your gut....most front-end "clunks" usually originate from the "floating" disc brake rotors moving slightly on their mounts.

 

[FJRay]

I would do the springs for sure. 03 springs are mush and if you weigh more than about 150 then they are just ****. My 03 still has original seals and bushings with over 100k on them and no clunks or leaks. I put Eibach springs in it early on and change fork oil every other spring along with the rest of the fluids. I use 7.5 wt Silkolene fork oil. YMMV

 

[audiowize]

Well, I nabbed a new set of 2004 springs for $35 (how are they that inexpensive?). This is quite a deal compared to the ~$80 for true 2003 fork springs.

If I can snag it cheaply enough, I may toss a gen 2 rear shock on for good measure.

 

[rickysnickers]

My '05 used the clunk. I replaced the ball bearing headset with a tapered roller bearing set and it went away. Food for thought.

 

[audiowize]

So, when refilling the fluid, I put in more than I need, pumped the shocks a bit till I couldn't hear anymore bubbles, then pushed everything down to suck fluid out till I had 100mm between fluid and the top of the fork.

What I noticed is that the spring is in the way. The service manual is oh-so vague, they kind of mention checking the springs, but they never really say when to put them back in. Since they were in the way, I took them out and set the fluid level to 100mm, then put them back in and put everything back together. Is this the correct procedure?

 

[MCRIDER007]

So, when refilling the fluid, I put in more than I need, pumped the shocks a bit till I couldn't hear anymore bubbles, then pushed everything down to suck fluid out till I had 100mm between fluid and the top of the fork.
What I noticed is that the spring is in the way. The service manual is oh-so vague, they kind of mention checking the springs, but they never really say when to put them back in. Since they were in the way, I took them out and set the fluid level to 100mm, then put them back in and put everything back together. Is this the correct procedure?

Sounds like it. You set the oil level with the fork tube compressed and the springs out.

 

[audiowize]

So, with 2004 springs in my 2003, are there recommendations regarding a stiffer rear shock? Would a used 2008 rear shock be helpful (less squish)?

 

[MCRIDER007]

So, with 2004 springs in my 2003, are there recommendations regarding a stiffer rear shock? Would a used 2008 rear shock be helpful (less squish)?

The GEN2 shocks have slightly heavier springs than the 04/05 shocks but the GEN3 shock is far superior with even heavier springs and much improved damping.

 

[audiowize]

I'm also considering just replacing the spring with the Hyperpro spring, as that ought to deal with the weight issue.

 

[Afast03nNJ]

I did the Hyperpro set up (both front and rear) on my 03 with a new OE rear shock. It completely transformed the way the bike rides and handles. A huge bang for the buck. Look for a slightly used newer rear shock on here and get the HP springs. You'll love the new ride and handling.