Installing extended fork tubes can greatly improve the look and performance of your motorcycle. Whether you’re looking for a more aggressive stance or want to accommodate a larger wheel, extended fork tubes can be a great modification. While the process may seem daunting, it can be easily done with the right tools and knowledge.
Step 1: Gather the necessary tools
Before you begin the installation process, make sure you have all the necessary tools on hand. You will need a motorcycle lift or stand, a socket set, a torque wrench, a fork seal driver, and a fork oil. Additionally, it’s recommended to have a service manual for your specific motorcycle model to guide you through the installation process.
Note: The specific tools you need may vary depending on the make and model of your motorcycle, so be sure to consult your service manual.
Step 2: Prepare your motorcycle
Prior to installing the extended fork tubes, it’s important to prepare your motorcycle. Start by placing your motorcycle on a lift or stand to ensure stability during the installation process. Then, remove the front wheel, fender, and brake caliper to access the fork tubes.
Tip: It’s helpful to take pictures or make notes of your motorcycle’s current setup before disassembling any components. This will make reassembly easier later on.
Step 3: Remove the stock fork tubes
Using your socket set, carefully loosen and remove the upper and lower triple clamp bolts that secure the stock fork tubes. Once the bolts are removed, gently slide the fork tubes out of the triple clamp and set them aside. Be cautious when handling the fork tubes as they may still have residual oil.
Caution: The stock fork tubes may be heavy, so use caution when removing them to avoid injury.
Step 4: Install the extended fork tubes
With the stock fork tubes removed, it’s time to install the extended fork tubes. Begin by sliding the extended fork tubes into the triple clamp, making sure they are fully seated. Then, reattach the upper and lower triple clamp bolts and tighten them to the manufacturer’s specifications using a torque wrench.
Tip: It’s crucial to follow the torque specifications provided by the manufacturer to prevent any damage or failure of the fork tubes.
Step 5: Reassemble your motorcycle
Once the extended fork tubes are securely installed, it’s time to reassemble your motorcycle. Reattach the front wheel, fender, and brake caliper, ensuring everything is positioned correctly. Finally, refill the fork tubes with the appropriate amount and type of fork oil according to your motorcycle’s specifications.
By following these steps and taking your time, you can successfully install extended fork tubes on your motorcycle. However, if you are not comfortable or experienced with motorcycle modifications, it’s best to seek the assistance of a professional mechanic. Safety should always be the top priority when working on your motorcycle.
Important Tips for Installing Extended Fork Tubes
1. Measure and Verify:
Before purchasing extended fork tubes, measure the length of your current fork tubes to ensure that you are getting the correct size. Verify the measurements with the manufacturer or seller to avoid any compatibility issues.
2. Gather the Necessary Tools:
Make sure you have all the tools required for the installation process. This may include a socket set, a torque wrench, a thread lock compound, and any specialized tools recommended by the manufacturer.
3. Secure the Motorcycle:
Park your motorcycle on a flat and stable surface. Use a motorcycle stand or lift to elevate the front end, ensuring that the motorcycle is stable and won’t tip over during the installation process.
4. Follow the Manufacturer’s Instructions:
Read and understand the manufacturer’s instructions and guidelines for installing the extended fork tubes. Follow the steps carefully to avoid any mistakes or damage to the fork tubes.
5. Drain the Fork Oil:
If your motorcycle has fork oil, drain it before removing the old fork tubes. Refer to your motorcycle’s manual for the proper procedure to drain the fork oil. This step will prevent any spills and make the removal process easier.
6. Remove the Old Fork Tubes:
Detach the front wheel, brake calipers, and any other components that may obstruct the removal of the old fork tubes. Loosen the triple clamps or any other fasteners holding the fork tubes in place. Carefully slide out the old fork tubes from the triple clamps and remove them from the motorcycle.
7. Install the Extended Fork Tubes:
Apply a thin layer of thread lock compound to the threads of the new fork tubes. Carefully slide them into the triple clamps and ensure they are properly aligned. Tighten the triple clamps or any other fasteners according to the manufacturer’s torque specifications.
8. Refill the Fork Oil:
If your motorcycle uses fork oil, follow the manufacturer’s instructions to refill it. Be sure to use the correct type and amount of fork oil recommended for your motorcycle model.
9. Reassemble the Components:
Reinstall the front wheel, brake calipers, and any other components that were removed during the installation process. Double-check that all fasteners are tightened to the manufacturer’s specifications.
10. Test and Adjust:
After completing the installation, take your motorcycle for a test ride. Check the suspension and handling to ensure everything is working properly. If necessary, make any necessary adjustments to the fork tubes’ alignment or suspension settings.
Remember to always consult the manufacturer’s instructions and guidelines for your specific motorcycle model. If you are unsure about any step of the installation process, it is recommended to seek professional assistance.
Preparation and Tools
Before you begin installing extended fork tubes, it’s important to gather all the necessary tools and prepare your workspace. Here’s what you’ll need:
Tools
- Socket set with metric and standard sockets
- Wrench set
- Torque wrench
- Measuring tape
- Allen wrench set
- Screwdrivers (both flathead and Phillips head)
- Cable ties
- Lubricant
- Jack or motorcycle lift
Workspace Preparation
Make sure you have a clean and open workspace to work in. Clear out any tools or debris that might get in the way. If you’re working in a garage, consider using a drop cloth or old towels to protect the floor from any potential spills or scratches.
Set up your jack or motorcycle lift to elevate the front end of your motorcycle. This will provide you with easier access to the fork tubes during the installation process. Make sure that your motorcycle is stable and secure before beginning work.
Lastly, it’s always a good idea to consult your motorcycle’s manual for any specific instructions or guidelines related to fork tube installation. This will ensure that you follow the manufacturer’s recommendations and maintain the integrity of your motorcycle.
Removing the Old Fork Tubes
The first step in installing extended fork tubes is to remove the old ones. This process may vary slightly depending on the specific motorcycle make and model, so it’s always a good idea to consult the owner’s manual for instructions specific to your bike. However, the following general steps can serve as a guideline for most installations.
Gather the Required Tools
Before you begin, make sure you have all the necessary tools on hand. Some common tools you may need include:
- Socket wrench set with various sizes
- Allen wrench set
- Torque wrench
- Pliers
- Hammer
Support the Front End of the Motorcycle
To safely remove the fork tubes, you’ll need to support the front end of the motorcycle. Use a motorcycle lift or center stand to keep the bike stable and secure. If you don’t have access to these tools, placing the bike on a sturdy flat surface with blocks or other support can also work, as long as it’s stable.
Disconnect the Front Brake Caliper
Start by removing the front brake caliper. Use a socket wrench to remove the bolts securing the caliper to the fork leg. Then, carefully slide the caliper off the brake rotor and hang it somewhere secure so that it doesn’t dangle by the brake line.
Loosen the Fork Clamp Bolts
Next, locate the fork clamp bolts that secure the fork tubes to the triple tree or upper fork clamp. Use an Allen wrench or socket wrench to loosen these bolts, but do not remove them completely just yet. Loosening them will allow the fork tubes to slide out more easily later in the process.
Remove the Fork Tube Caps
Once the fork clamp bolts are loosened, remove the fork tube caps. These caps are typically located at the top of the fork tubes and may be held in place with bolts or plugs. Use the appropriate tools to remove these caps and set them aside in a safe place.
Slide Out the Fork Tubes
With the fork clamp bolts loosened and the fork tube caps removed, it’s time to slide out the old fork tubes. Gently pull the fork tubes out of the triple tree or upper fork clamp, being careful not to damage any surrounding parts or wiring. It may be necessary to slightly wiggle or twist the tubes to help them come out smoothly.
Once the tubes are completely removed, inspect them for any damage or wear. If necessary, replace them with the new extended fork tubes and proceed with the installation process.
Installing the New Extended Fork Tubes
When it comes to installing extended fork tubes on your motorcycle, it’s important to follow the proper procedure to ensure a safe and successful installation. Here are the steps you need to take:
1. Gather the Necessary Tools and Materials
- Extended fork tubes
- Socket set
- Wrenches
- Tape measure
- Torque wrench
- Thread lock
- Shop manual for your motorcycle
2. Prepare the Motorcycle
Start by parking your motorcycle on a flat surface and securing it with a stand or wheel chock to prevent it from falling over during the installation process.
3. Remove the Front Wheel
Using a socket set and wrenches, loosen and remove the axle nut and then remove the front wheel from the motorcycle. Place the wheel aside in a safe location.
4. Drain the Fork Oil
Refer to your motorcycle’s shop manual for the specific instructions on how to drain the fork oil. Typically, this involves loosening the drain screws and allowing the oil to fully drain into a container.
5. Remove the Fork Tubes
Using the appropriate tools, loosen and remove the bolts and clamps that hold the fork tubes in place. Slowly slide out the old fork tubes and set them aside.
6. Install the New Extended Fork Tubes
Take the new extended fork tubes and apply a small amount of thread lock to the threads. Carefully slide the fork tubes into the triple tree, aligning them with the fork seals and dust covers. Use a torque wrench to tighten the bolts and clamps to the manufacturer’s recommended specifications.
7. Refill the Forks with Oil
Refer to your motorcycle’s shop manual for the specific instructions on how to refill the forks with oil. Pour the recommended amount and type of fork oil into each fork tube, and then tighten the fork caps back on.
8. Reinstall the Front Wheel
Place the front wheel back onto the motorcycle and tighten the axle nut to the proper torque specification. Ensure that the wheel is straight and aligned with the forks before tightening the axle nut fully.
9. Test the Suspension
With the motorcycle still supported by a stand or wheel chock, compress and release the front suspension several times to check for any abnormalities or issues. If everything feels and looks in order, proceed to the next step.
10. Double-Check Everything
Before taking your motorcycle on the road, double-check all the bolts, clamps, and other parts to ensure they are properly tightened and secured. Look for any loose or missing components and tighten or replace them if necessary.
By following these steps, you will be able to successfully install the new extended fork tubes on your motorcycle. Remember, if you are not confident in your mechanical abilities, it’s always best to seek professional assistance to ensure the job is done correctly and safely.
Testing and Adjustment
After installing the extended fork tubes, it’s important to test and adjust the suspension to ensure optimal performance and safety. Here are the steps to follow:
Step 1: Compression Test
Start by performing a compression test. This will help you determine if the fork tubes are properly adjusted for your bike’s weight and riding style. Follow these steps:
- Place the motorcycle on a stand so that the front wheel is off the ground.
- Using a tape measure, measure the distance from the bottom of the lower triple clamp to the center of the front axle. This is your initial sag measurement.
- With the front wheel off the ground, fully compress the front suspension by pressing down on the handlebars. Be sure to stabilize the motorcycle to prevent it from tipping over.
- Release the suspension and measure the distance from the bottom of the lower triple clamp to the center of the front axle again. This is your compressed sag measurement.
- The difference between the initial sag and compressed sag measurements should be around 25-35mm. If the difference is significantly less or more, adjustments need to be made.
Step 2: Rebound Test
Next, you’ll need to perform a rebound test. This will help you determine if the fork tubes are rebounding at the appropriate rate. Follow these steps:
- Place the motorcycle on a stand so that the front wheel is off the ground.
- With the front wheel off the ground, fully compress the front suspension by pressing down on the handlebars.
- Release the suspension and observe how quickly the forks rebound. They should rebound in a controlled manner without bouncing excessively.
- If the forks rebound too quickly and feel harsh, you’ll need to adjust the rebound damping. If they rebound too slowly and feel mushy, you’ll need to reduce the rebound damping.
Step 3: Preload Adjustment
Lastly, you’ll need to adjust the preload on the fork tubes. Preload is the amount of compression applied to the fork springs before riders’ weight is added. Follow these steps:
- Find the preload adjusters located on the top of each fork tube.
- Use a spanner wrench or an appropriate tool to turn the preload adjusters clockwise to increase preload or counterclockwise to decrease preload.
- Make small adjustments and test ride the motorcycle after each adjustment to evaluate the impact on your riding experience.
- The preload should be set based on your weight, riding style, and the manufacturer’s recommendations.
By following these testing and adjustment steps, you’ll ensure that your extended fork tubes are properly set up for your bike, providing optimal suspension performance and enhanced riding experience. Remember to refer to your motorcycle’s owner’s manual for specific instructions and specifications.
Summary
Proper testing and adjustment of the extended fork tubes is crucial for optimal suspension performance and safety. Follow the steps outlined above to perform a compression test, rebound test, and preload adjustment. Make necessary adjustments based on the results and your riding experience. Always refer to your motorcycle’s owner’s manual for accurate specifications and instructions.
