Daytona 900 (1996 Some Tlc)

New seals and a polish up, pads, pins, and fixing bolts !!





Tested the calliper before mounting back on the bike, just need to do the same all over again for the other !!!

 

I think I'd need group therapy if it ever went down !!

 

Cheers, doing this sort of stuff fits well with my OCD

 

No but I'll pop one off tomorrow and measure it for you

 

I was guessing, but by the state of other bits on the bike the fork oil had never been changed. Never serviced forks before so scanned quite a bit of info on how to tackle it. Also the paint on the forks was in poor condition in some places, and I was hoping to move to a polished finish instead. Was'nt sure how this was going to turn out but worth a try


As you can see they're not in the best of shape, no leaks though.

Popped out the bolts a the bottom holding the damper mechanism in, held the body in a workbench, dust seal and spring clip out, then yanked at the inner fork until the top bush popped out.



I don't know f this is normal but the oil that came out was pitch black, and absolutely stunk. Must have been the original oil



I've used Nitromors in the past for getting old paint off and it did the job on the forks



The nitromors did most of the work but they needed a good graded polish


I used an orbital sander and a Dremel to clean the forks up, and started with 500 grade to 1500 and finished up using some "Mothers Mag & Aluminium Polish" (never used this before but sore a guy on YouTube using it and his results were good



I spent about an hour on each fork, they were far from perfect but they were going back on a bike that had a few scars during it's life

 

New fork seals, i'd love to take the credit for this DIY seal replacement but a guy on YouTube used electrical tape wound round the tube (a couple of mm) and used the action of the fork to drive in the seal and bush. This worked an absolute treat thumbs up to that Guy


Replacing the oil was straight forward, springs and damper adjust removed from the top and oil replaced to the specified height. Used a bit of tube set at the correct depth to remove any access



Then remove air from damper mechanism

Top back on and they feel nice

 

Thanks Dave for your reply, should get it all back together again by Friday. I'm having the wheels powder coated gloss black as we speak, it's all a matter of taste but i thought the gold wheels looked a bit tooooooo blingey with the red. Also they needed doing as they had started to chip. Looks like they were painted with standard can spray.

 

Hi, As you can see it's elliptical, 63mm high and 58mm wide

 

Just been doing some cosmetic changes, at some point some red engine casing bolts were use to replace the original steel one's. I'm not a fan of these aluminium pins as they tend to break, sees, or chew up. I had to drill out both pins out of the forks, nasty things.



Better me thinks


Gave the swing arm blanks a polish as they were painted silver !!!


Blings ok you just need to be careful how much you use

 

Neutral light flickered and failed to come on sometimes, you can see where the brass/copper sprung post had warn down considerably



Testing on the bench showed a complete fix

The white lettering from the indicator panel had nearly warn off

 

Interesting, never seen that amount of corrosion, I did slap loads when putting them together but not under the seal. I have seen the black version


If or when I get any trouble with them they will go on eBay or the bin which ever comes first !!

 

Happy with the look to date, just waiting for the wheels to be painted

 

Just need some decent rubber now !!