shortening forks - honda · shortening forks author: hondachopper.com created date: 1/12/2011...

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Shortening Forks Shortening Forks Shortening Forks Shortening Forks Step by Step Courtesy of Bigmcgiv and Olgraybeard ...Back...|...The Garage...|...Hondachopper.com's Index... . Remove fork cap and remove drain screw

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Page 1: Shortening Forks - Honda · Shortening Forks Author: hondachopper.com Created Date: 1/12/2011 8:04:49 AM

Shortening ForksShortening ForksShortening ForksShortening ForksStep by Step Courtesy of Bigmcgiv and Olgraybeard

...Back...|...The Garage...|...Hondachopper.com's Index...

.

Remove fork cap and remove drain screw

Page 2: Shortening Forks - Honda · Shortening Forks Author: hondachopper.com Created Date: 1/12/2011 8:04:49 AM

Now pump the fork and drain oil

Page 3: Shortening Forks - Honda · Shortening Forks Author: hondachopper.com Created Date: 1/12/2011 8:04:49 AM

Remove the allen screw at the bottom of the fork

Page 4: Shortening Forks - Honda · Shortening Forks Author: hondachopper.com Created Date: 1/12/2011 8:04:49 AM

Remove the spring cap on top

Page 5: Shortening Forks - Honda · Shortening Forks Author: hondachopper.com Created Date: 1/12/2011 8:04:49 AM

Now the fork is disassembled.

Page 6: Shortening Forks - Honda · Shortening Forks Author: hondachopper.com Created Date: 1/12/2011 8:04:49 AM

Remove the dust boot, seal retainer spring, and old seal.

Page 7: Shortening Forks - Honda · Shortening Forks Author: hondachopper.com Created Date: 1/12/2011 8:04:49 AM

Install new seal [with the special tool].

Page 8: Shortening Forks - Honda · Shortening Forks Author: hondachopper.com Created Date: 1/12/2011 8:04:49 AM

After seal is installed replace retainer spring and dustboot.

Page 9: Shortening Forks - Honda · Shortening Forks Author: hondachopper.com Created Date: 1/12/2011 8:04:49 AM

Now the spring . Place it into the vice to hold.

Page 10: Shortening Forks - Honda · Shortening Forks Author: hondachopper.com Created Date: 1/12/2011 8:04:49 AM

Measure down from the top 1 3/4 inches which is about 7 turns and cut.

Page 11: Shortening Forks - Honda · Shortening Forks Author: hondachopper.com Created Date: 1/12/2011 8:04:49 AM

Note: Cut close to the same angle as the top of the spring

This is what it should look like after the cut

Page 12: Shortening Forks - Honda · Shortening Forks Author: hondachopper.com Created Date: 1/12/2011 8:04:49 AM

Now the piston. i got two 2" bronze bushings 1" od and 3/4" id at the local hardware store.

Install on piston as shown

Page 13: Shortening Forks - Honda · Shortening Forks Author: hondachopper.com Created Date: 1/12/2011 8:04:49 AM

Now that the mod is done time to reassemble. Slide the spring into the tube.

Page 14: Shortening Forks - Honda · Shortening Forks Author: hondachopper.com Created Date: 1/12/2011 8:04:49 AM

Install tube in the lower and reinstall the lower with the allen screw.

Page 15: Shortening Forks - Honda · Shortening Forks Author: hondachopper.com Created Date: 1/12/2011 8:04:49 AM

Measure the fluid of choice (atf/ fork oil/ 10w30). I used atf. 6 oz and pour in the top of fork.

Page 16: Shortening Forks - Honda · Shortening Forks Author: hondachopper.com Created Date: 1/12/2011 8:04:49 AM

Reinstall top cap

Note: These old springs i cut at 1 3/4 inches for some preload.

Page 17: Shortening Forks - Honda · Shortening Forks Author: hondachopper.com Created Date: 1/12/2011 8:04:49 AM

Now we are done. Repeat process for other side.

Page 18: Shortening Forks - Honda · Shortening Forks Author: hondachopper.com Created Date: 1/12/2011 8:04:49 AM

Finished product. Looks good!

I hope this helps some with their build.

Bigmcgiv

According to Olgraybeard the shocks don't bottom out and

the stiffness/ride is pretty much same as stock.

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