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Discussion Starter · #1 ·
The front forks are getting leaky and soft, time for a rebuild. What parts am I going to need and will I need any specialty tools? Anything unusual to be aware of? Thanks in advance.
 

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Just did this on my 81 a few months ago. No special tools needed, just a fairly large wrench to take to top cap off, and then a large metric allen wrench to take out the nut at the top of the tube under the cap. I ordered the below. You can skip the spring, but it was available and only 3 bux so I said why not. You need QTY 2 of everything for the pair of tubes. Good luck.

51412-369-000 SPRING, FR.
51437-413-003 RING, PISTON
90601-369-000 RING, OIL SEAL STOP
91254-413-881 DUST SEAL, FR. FORK
91255-413-881 OIL SEAL (33X46X11)
94608-30000 O-RING (23X2.4)
 

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Hey 1980CM400E, how did your rebuild go? I need to do the same and have basically the same question you posted...
 

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It's all covered in the manual, Galt. That bolt in the bottom is a 6 mm allen . Here's a pic of them apart.

20160830_161600.jpg
 

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It's all covered in the manual, Galt. That bolt in the bottom is a 6 mm allen . Here's a pic of them apart.

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Okay cool, thanks. Just wanted to be sure before I order anything.
 

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Those darn hex holed nut rings can be the devil to get back in with an allen key, so I made a useful tool from a flanged 14mm a/f bolt, welded to a suitable "T" handle. I ground the bolt hex head down to reduce the "height".

Re fitting those allan rings is now childs play with good control and no real chance of cross threading at all. Of course, you may know different.

I also made a holder for the fork with the 2 studs, just a metal strip with 3 holes in the right place of the right diameter, making that side so easy to remove the allan bolt.

A fork holding tool can be used via a large adjustable spanner across the flats of the fork bottom, for the speedo side.

Leave the forks in situ to undo the bottom allan bolts, so much easier.

See manual for correct spring fitting.

Everything else with this job is more or less straight forward.

Do your forks have the replaceable bushes??
 

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Discussion Starter · #8 ·
Sorry for the long wait, the rebuild went great. Once you have them off it's pretty straightforward. Although mine were pretty rough so it took awhile to get them cleaned up enough to be decent.
 
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