how to remove rust from motorcycle front forks

Fork seals on my 09 Hammer S are in need of replacement, local shop informed me that the kit has been discontinued. The Tiger was re-introduced after WWII much the same as before hostilities. Rust Removal Steps: 1) First step, is to flush the tanks the best you can with water. We will send E-mail out when we have our Grand Re-opening. Now you'll need a special tool. front forks "clunk" on rebound after going over drops / into potholes ... And after 3 or 4 days starts to leak from a seal because i had rust on the stanchions and the seals just got scratched. Persistent rust may require you to add your agitators. Dry Your Motorcycle. Remove both fork assemblies and set aside for disassembly. This is obviously (from the images) a suspension fork, and a very low-end one. Like, who needs to research how to wash motorcycles, or how to check your air pressure? Removing small rust spots on front fork 16-09-2011, 10:52 AM. When your motorcycle is supported, remove the front wheel from your motorcycle’s fork and then disconnect the brakes. Use a high-pressure water nozzle to wet the bike, covering all aluminum surfaces. DESCRIPTION EAU10410 Left view 1. Depending on your bike's model, you may also need to loosen or remove brake hose clamps, the handle bars, or air caps. Besides the degraded suspension performance (which could be ignored if it's only intended to bash around off-road), leaking oil can get into the front brake, which you don't want.. looks like corrosion is coming through the clear coat, only way to fix properly is rub back the whole lot with 400 wet and dry (or sandblast) then graduate to 600 then 1200, then use an aluminium buffing compound and a buffing wheel. Here is a front fork assembly, wheel, and front fender removed from a 5600 mile 1962 Matchless G12 CSR survivor motorcycle. The vinegar process is meant to remove the rust you can’t get off on your own. Set the forks on a clean work area. I will go into greater detail about this particular paint in some of my newer posts. Not sure about the pitted areas, but I generally remove light rust by putting oil on the part and gently rubbing with very fine steel wool, taking care to wipe the debris off often to reduce … Re: 1998 Honda goldwing front forks rebuild. coka cola/coka-cola takes the rust and corrosion off of your motorcycle harley honda exhaust quick and easy in 5 minutes In the list below I show parts for the earlier (up to 1975) and later (1976 and on) ATE disk brakes. After going over it and checking it out up close I found out it had been in some sort of crash. Taking off the wheels really opens up some hard to reach places, like around the rear swing arm, the underside of the rear section of frame (where a lot of rock chips happen over the years), the front forks, etc. There is usually one large bolt located between the base of the tank and the very front of the seat. The main reason for fixing up the front forks was that the dust covers were deteriorating. MOTORCYCLE CARE AND STORAGE EAU26060 ucts onto seals, gaskets and wheel thinner, fuel (gasoline), rust re- Care axles. Hammerite Direct to Rust Metal Paint Hammered Blue 750ml. 1. Depending on the level of rust, this step could last anywhere from over night to a couple of days. 1. Use the balled up aluminum or tin foil to scrub the rust off. The tension of the spring will help to push the forks down and out. send the part to be media blasted on the pitted areas (not sand blasted! Any guidance much appreciated. This will work best on chrome and sometimes on bare steel. id, antifreeze or electrolyte. Wax the motorcycle to provide a barrier between it and moisture. Suspension forks are heavier than their rigid counterparts, but the trade-off is that they absorb shocks. Step 2 – Remove rear fender. 4.1: How to remove rust from Motorcycle exhaust pipe First, take the sandpaper and scrub to the rusted parts of the exhaust pipe. Then applied paint stripper to get rid of the clear coat. Remove the chrome bolts (these are also the fork oil caps) securing the tubes to the upper triple clamp. by Duane Ausherman. 4. This should remove the majority of the rust. Step 3: Remove the fork tubes from the bike by loosing the triple clamps bolts. The first thing I did was to apply penetrating oil and leave it over night. I am at 31K and will be changing my fork oil soon. Step 1: Wipe the fork tube down with contact cleaner and a rag to remove debris from the surface. Slide the forks out from the bottom of the triple clamp. Everything had rust on it, EVERYTHING! The reason is that the spring exerts a lot of force down on the top of the damper assembly. Remove the brake calipers and front wheel from the forks. Here are the parts at the lower end of the fork slider, in order from left to right. Nov 2, 2020 - Explore David Geer's board "bikes" on Pinterest. Some motorcycle DIYs and how-tos are easy. Take a plastic or glass tub and make a solution water and hydrochloric acid. Always rinse the dirt and de- movers or inhibitors, brake flu- While the open design of a motorcycle greaser off with water. ... black and has a metallic sheen to it, you know that is bushing surface material. Once the seat and the struts are removed, the fender can be taken off and set aside. getting the rust off. ), then … ". You really need a shop manual. And before fitting a set of used girder forks, make sure they’re up to the job. Thus far, Chassis Saver is the only paint I have found that really does the job. You can also take a small piece of cloth and make it completely wet with … Remove the chain from the cog and front wheel. Hey there, I googled 'remove rust from chrome', and found a page that advised using aluminium foil, wetting it down and balling it up, then rubbing that across the frame. We manufacture motorcycle fork-tubes. Pull the end of the cable out of the speedometer. Cola – Using Cola works best when used in conjunction with the balled up aluminum foil. 00:16 - Bronze or brass wool works the best. Remove the brake calipers and front wheel from the forks. This has become evident in other places as well, ( 2009 Victory HAMMER/HAMMER SPORT ALL OPTIONS (V09HB36/HS36) Suspension, Front Forks, Marzocci All Options | PartsPitstop.com) see grouping 21. The metal “top hat” fits on the front end of the piston and I reused the existing one. Front fork rebound damping force adjusting screw (page 3-23) 10.Engine oil filter cartridge (page 6-13) 4. May 17, 2016 - Auction Lot S90, Schaumburg, IL 2016. I've used it on motorcycle pipes to remove blue exhaust stains, and it will remove light rust from chromed surfaces like handlebars, and front forks. Connect the Neg (black -) with the lead Cathode and the Pos (Red +) with your item. My bike is a 2007 900 Custom. Fork Rust Removal. Remove the rear wheel to get at your motorcycle’s rear drum brake. If you are working on some other part, clean it with a regular degreaser, sandpaper, and/or a wire brush. there is one option not mentioned here. These parts are in excellent shape for being from a rare 60 year old motorcycle. 2: I used 1200 grade wet/dry only and a lot of elbow grease. Stabilize the motorcycle on its kickstand, or utility kickstand, on a concrete surface that has good drainage. Remove the Forks. 3. Get fine-grit sandpaper about 1500 fine but finer the better is good at removing stubborn rush. Thank you for being patient in the mean time. Replace the front brake pads as well. Place the motorcycle on a stand or lift. Front fork spring preload adjusting bolt (page 3-23) 9. I keep a bike in my dads garage in Florida and it's starting to show a few rust speckles on the forks that I want to handle. A leaky motorcycle fork seal is more than just an eyesore. See more ideas about bicycle, bike, cargo bike. When drying off your … Make sure the forks are installed at the same height in the trees, this can cause uneven damping (shock absorbing quality) and make taking turns (curves) a bit scary as the front end will shake. Let’s get started. Using a socket wrench, loosen the pinch bolts on the upper and lower triple clamps. Motorcycle Tool Bag, Universal PU Leather Motorcycle Fork Bag Saddlebags Handlebar Bag Sissy Bar Storage Tool Bag for Honda Kawasaki Suzuki Yamaha Sportster (Black-1) … Fill the tank 1/4 full with a dish detergent and water solution. Add 30 ml (30%) hydrochloric acid for each Litre of water. The foil is softer than chrome, so shouldn’t scratch the surface, but the idea is to use the chemical reaction to clean the rust off, not brute force. Follow the directions of the rust removing product for the best results. Only use cleaners and waxes specifically formulated for matte paint. Fuse box 2 (page 6-34) 8. Grab a piece of pure lead and hang it into the solution. You need to slow the rpm down on the buffer, so you don't wear all the compound, and it'll work really well. 30 plus years of rust. In this short video we’ll learn how to remove surface rust. Where the fork tube goes into the fork leg there is a rubber dust cover. With the bike suitably supported, remove the front wheel and the front fender. Step 1: Remove the speedometer cable. Place the motorcycle on a stand or lift. Remove the brake calipers and front wheel from the forks. Using a socket wrench, loosen the pinch bolts on the upper and lower triple clamps. Slide the forks out from the bottom of the triple clamp. Rust on parts of your bike can change your ride from been enjoyable to a lot more challenging activity especially if the bike forks are being too rust. Not only affecting your ride but the existence of the rust on the bike can also turn your shiny bike looking like complete junk. Remove any cable guides on the front forks or the handlebars of the motorcycle. First, remove the fork drain screws and drain the old oil. (Just in case, though, we have you covered.) Clean the Rusted Spots. The forks should be rebuilt with new seals and bushings. Rub gently. Let me insert a safety note here. You need to do this gently. Once safely aloft, remove the brake caliper(s), speedometer cable, front fender, and front wheel. The brakes can be removed by loosening the four bolts that support the brake calipers and the pinch bolts which are present on the front of the front leg. But any imperfections to the chrome can tear the seal, allowing the oil to leak out. The upper end of each fork tube is choked down and fits hard up inside the upper triple clamp. Installing, adjusting, aligning, and greasing the front and rear swingarm on the Earles fork BMW motorcycle. Slide the forks out from the bottom of the triple clamp. Set the forks on a clean work area. Prepare the forks by removing the painted or anodized finish from the fork tubes. Spray the fork tubes with an aircraft-grade paint stripper to remove paint. For this job you’ll need some light oil, a chunk of fine steel wool, and a rag. If there is any play or if the if the forks do not turn from stop to stop smoothly, adjustment or repair is indicated. 2. How To: Remove Rust from Chrome Though a chrome finish goes a long way to protect metal against corrosion, cracks can enable rusting. Loosen the speedometer cable connection fitting on the underside of the speedometer by turning it counterclockwise with pliers. Step 1: Separate the tire, inner tubing, and spokes from the bike wheels so that you are only remaining with the bike rims. do not use any oil. Bottom of Fork Slider, rubber cover, wave washer, 8 mm nut, fork plug, large copper ring, inner rubber bumper. You can also change the fork without removing everything from the bike, and using the drain screw on the bottom of the fork if your forks have one, but the best way is to remove the fork tubes. The corrosive agents attack these crystals instead of the metal. 5 With the forks clear, completely undo the fork cap and pull it up - you can't remove it, though, it's still attached to the fork's internals at this point. Make sure the calipers are supported, not dangling loose on their hoses. Slide the forks out from the bottom of the triple clamp. Peeking under the seals at the tops of the stanchions, there's definitely some rust in there. TIP: An old trick pro bikers recommend is dipping the shiny side of an aluminium foil in Coke or … Aluminum Foil – Make a ball out of the foil and dip it into some water. . Starting to remove the rust. If the forks are pitted, then the pitting will, in time, damage the seals, and they'll leak. After Rusting it thoroughly spray Vinegar. How to Remove Rust from Bike Rims. Shock absorber assembly rebound damping force adjusting screw (page 3-25) 2. Removing the front motorcycle wheel is even easier than the rear. Drain and remove all the old oil from the front forks and the engine. If rust pitts have developed on the inner tube the rebuild will not last. How to Remove Rust for Less Than a Dollar. We carry past models from the 1950s through today's models. remove the rust by whatever means you can. Remember this trick for later. They have to be placed back in the same place back on the motorcycle so the wheel does not wobble after replacement. The slender tubes used on Webb/Brampton forks are especially prone to rusting from the inside. They are then built up with hard chromed over and above there original size. Simply soak the item in the desired WD-40 for a predetermined amount of time, then rinse or scrub the rust away. This creates a lot of friction, which hopefully keeps the damper rod from spinning while trying to remove the nut. PROCESS. Removed the front mud guard / fender - comes out from the opposite side to the stand. Each time the fork goes up and down over the rust pitts, it … Rust is a pesky thing to encounter, but luckily, it can be removed with the use of the WD-40 multi-use product or the WD-40 Rust Remover Soak. Bust rust fast with any of these four methods. Step 2: Use a flat head screw driver to pull the seal scraper down. Removing the forks is relatively easy compared to installing them. With the front wheel pointing straight forward, grasp the lower fork legs with your hands and try to move the forks forwards and backwards. This can be a little tricky. If your rust is really bad you may have to get the part sandblasted and re-chromed. Align the pin of a link removal tool against a pin within a chain link. Use a mild dish-washing soap, bucket and detailing brush to clean the aluminum surfaces, removing all road grime -- mud, oil and dirt. Bill. It is about a four hour job to do this. New Carb. Then check the fork tube for pitting in the chrome or rust. Tabasco sause work well as a penetrating fluid or a mixture of 1/2 lacquer thinner and 1/2 automatic transmission fluid. Ashford Chroming can re-hard chrome your motorcycles pitted forks, stanchions and re-grind them to their original size, making them better quality than new and to UK Motorcycle MOT standards.. Step 2: remove the front wheels, brake calipers and mudguard. Fork reconditioning is often cheaper than buying new replacement forks and to mostly superior standards. Page 78 MOTORCYCLE CARE AND STORAGE After normal use ECA10790 5. Dip the clean towel into the box and wipe the wheel thoroughly with the cornstarch. This process should be covered in a shop … I have an old MTB which has been gathering dust in the shed, but the front forks which have silver tops (chromeor aliminium???) Turn the bike upside down, setting it on the seat and handlebars. The rear shoes and springs are typically sold as a unit and should be replaced. I have had problems removing the front forks on my first K2. After washing, use old rags to dry off your motorcycle. After removing the front wheel, remove the front fender. Add 30 1/4-inch diameter steel … I made a special tool out of PVC pipe for this task also. If you want to use Coke (it has some phosphoric acid in, so does do something), we recommend Diet Coke – it’s less sticky. Step 2: Use a flat head screw driver to pull the seal scraper down. Used a medium wet or dry pad wet in soapy water the same water I used to remove the paint stripper residue - rubbed in the direction of the polish lines - around the forks. Set the forks on a clean work area. Step 2: Remove the axle by removing the end caps on the bottom of the forks. I got new (used) forks on ebay for $30. This explained why the forks would not compress properly, they were bent to hell. The forks were removed and polished before being rebuilt. Take off the gas tank. Engine Oil and Fork Oil. Using a socket wrench, loosen the pinch bolts on the upper and lower triple clamps. At least the forks haven't seized in the compressed position - the bike's perfectly ridable as is (with the exception of the BB and some rusty cabling). 1: Use either an araldite or another epoxy resin. I use a die-grinder & Scotchbrite pads to get the the real ugly off, and the remaining clear coat. Many rust stopping paints, such as Rust-oleum, don’t really work. Step 2: Take the aluminum foil and dip it in a bowl of degreaser then let it soak for a few seconds. This is not a simple job but doable. Routine service combined with proper cleaning and inspection can extend the life and performance of your suspension product. Page 14: Right View If you can warm up the metal by placing in the oven on low heat or with a hair dryer, then use the coarse brown paper towels like … Some tanks have multiple bolts, but a lot of them only have this one bo… Use a polishing cloth to remove rust from hard to reach spots. I was going to sand it down but wasnt sure what it would look like afterwards lol after the rust is removed, there will be pitted areas. I bought the motorcycle in 2013 and I believe at that time it … Or simply leave the surface bare, and the crystals will inhibit future rust formation. Crank the tool until the link loosens and pops out. Place the motorcycle on a stand or lift. Then I use buffer discs and pads, and Semichrome polish to shine 'em up. A motorcycle shampoo like this Chemical Guys Hydrosuds Car Wash Soap is perfect for cleaning your motorcycle. Immediately after washing, remove excess moisture from chain and lubricate it with chain lube to prevent rust. First layer of paint. We can hard chrome and grind fork legs to original size. We stock over and under and stock lengths. Take off the front and rear wheels of the motorcycle and balance it. There can be some rust that is hard or just stubborn to remove. I figure it's easy enough and the fork oil has to be dirty, so I'll do it as part of my major service along with valve adjustment and coolant change. Now is a good time to clean the front of the motorcycle’s frame and fork … Once of the main reasons fork seals get damaged is through pitting and rust on the fork stanchion (or tube / slider) – as the tubes move up and down in the legs, the seals keep the oil in. This has shown to work well with motorcycle frames and proven tough durability. A loss of fork oil will at best degrade the damping performance and cause a failed inspection. Shift pedal (page 3-16) 3. Every tank is different, so make sure you know where all the tank bolts are located. At this point, the … Remove the gas tank and empty loose rust scale. Hi all, seeking some advice after I recently noticed some small rust spots on one side of the front fork. I tried it on a 1982 (25y.o) Apollo BMX that had been abused it's whole life, and it came up like new, with no scratching. Remove the front wheel, axle, fender, brake cables etc, unscrew the large fork tube nuts atop the top yoke and then loosen the pinch bolts on the lower yoke and then pull and twist each fork tube out. Besides the side bolts, there is … The slider covers can now be unbolted and removed if they are to be cleaned, painted, or replaced. Regularly inspect fork legs for cracks and signs of rust. Many manufacturers produced forks using different size tubing for different applications. One thing to pay close attention to is the inner or chrome portion of the fork. I see you've already replaced the seals once, so these fork stanchions are toast. Once completely dry, the surface is ready for the next step, whether it be painting, welding, plating, lubricating, etc. I finally decided to replace the carburator. Waxing painted and chromed areas such as the fuel tank, front forks and mufflers once a month adds protection to the those areas vulnerable to rust. DO NOT (I repeat, DO NOT) remove the slider tube plug (#10) and the fork spring. The first step is to remove the forks. 4 Undo the lower pinch bolts and slide the fork legs down and out, one at a time. I am trying to loosen it from the frame, but I can't loosen the bolt marked with 2 because of the rust and now it's completely gone. With routine 50 hour lower leg service, the fork will provide the necessary lubrication to the stanchions to perform properly until the next service interval is reached. I got run over a car a few weeks ago and now i have to change the fork. If using an acid, have your protective gear on as well. Remove the rubber o-ring inside the slider. It's an old racer, as you can see in the picture, with a 1 inch fork. Use Cola instead of water if the chrome is extra rusty. Use motorcycle shampoo and water to wash the surface. Loosen the triple clamp bolts that secure the fork leg, and pull the fork down and out with a twisting motion. White vinegar is best at … A little bit of Trans fluid and the seals, flushing the forks and some elbow grease and a shop manual is strongly advised. Telescopic forks were introduced and the mag/dyno was moved to the front of the engine. Remove surface rust from the fork tubes using a 600-grit sandpaper. Smooth the fork tube's surface, using coarse 150-grit sandpaper. Dip the sandpaper in a mixture of water and a mild soap and sand the fork tube, using a consistent back and forth motion. Smooth out any irregularities until the tube surface is uniform. I just couldn't get it adjusted due to the bad … Using Vinegar on Stubborn Rust Pour white vinegar into a spray bottle. The process consists of grinding the forks to remove pitting and any run out so they are perfectly parallel. While you do not need a lift or need to remove the rear tire, it helps a ton if you do so. Bar Keepers Friend – Pour a little bit of this into a small mixture of water to form a paste like substance. The master cylinder rebuild kit has all the rubber parts and all the metal parts–except for one “top hat”–and includes a new master cylinder piston. 3: You probably (with luck) will not need to take the forks off. PROCESS. metal polish only … Removing Stubborn Rust From Mountain Bike Forks. have rust spots, is there any way of getting rid of this? To remove any cornstarch powder, use compressed air. At worst the fork oil can coat the front brake disc and tire leading to an unsafe motorcycle. NOTE: Never use regular wax on matte finish paint. 5 Steps to Removing Rust From a Motorcycle Frame. ... Motorcycle sales process is basically the same thing with some small differences and rather different lender behavior, but the overall approach is the same. 68 Answers. Although the front forks were not leaking, the dust covers were very distracting for the look of the bike. This information applies to the models of BMW from late 1955 through 1969 and is the R26, R27, R50, R60, R69, R50/2, R50S, R60/2, R69S, R50US, R60US, R69US, models. FEATURES. The Sportster and Buell Motorcycle Forum - The XLFORUM® > SPORTSTER MOTORCYCLE FORUM > Sportster Motorcycle Suspension, Frame, Forks, Handlebars, Fuel Tank, Oil Tank, Fenders > Oxidized front fork, any ways to shine it up? 4. Being a 1979, I really had no idea when the fork fluid and seals had been replaced. Hard Chroming & Grinding Of Forks. There is no other after-market manufacturer of German, Spanish, or Japanese fork-tubes. Soak the chain … Do your best to remove the surface rust and grime. If the rust is harder to remove, then try is to get some fine-grit sandpaper. These rust spots MUST MEAN the fork has long ago COMPLETELY LOST its ability to work properly as a suspension. 8. Chrome-plated parts such as handlebars, rims, spokes, forks, and accessories may be further cleaned with automotive chrome polish. You don’t need to be a scientist to see the impact rust can have on metal if it’s left untreated. In 1949 the Tiger 100 was given new tank and headlamp nacelle Steering Bearings generally last a long time. The cornstarch will absorb the excess polish from the pores of the aluminum and eliminate any streaks in the finish. Cornstarch can be purchased at any supermarket. #3 • Jul 15, 2010. The best spray paint to use for a motorcycle frame is engine acrylic aerosol paint. Be sure to wipe dry when you are done with this initial step. The most important part of any painting job is the preparation. Don’t forget to reinstall them before the fork assemblies upon reassembly.

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