Rebuilding Front Forks

[JimmyG]

Hey guys and gals, I am rebuilding my front forks and have decided to get a fork seal driver, but cannot find the dimensions for which diameter our forks are. Been looking at videos, write ups on the process,etc.   I made the pvc tool, but just cannot get it to work quite like I think it should, so am going to get the proper tool.  Anyway, can someone confirm the proper diameter of the forks for me?  Thanks in advance

[Roidfingers]

I have some calipers. Where do you need me to measure. Can't measure inside, only outside, if this helps

[bill-jr]

http://www.valkyrieforum.com/bbs/index.php/topic,70292.0.html

Jimmy, maybe this will help?
When you get yours done let me know and ill let you do mine next ..

[hubcapsc]

I made a driver from PVC and it seemed to work OK. Then, later, I helped
a fellow do his forks and he had a "real" driver, and I liked it, so I got one.
I haven't used it yet, I guess I got the right one 



Here's a real handy PVC special tool:



Look in the manual (http://valkyrienorway.com/download.html) for a description of
another special tool you need...

The same site has an alternate how-to about taking
the forks apart: http://valkyrienorway.com/forksprings.html

-Mike

[JimmyG]

Don.t need the tool to remove springs, just the driver to seat the bushing, ring and seal.   It fits over the lower fork.   41 mm or 44 mm.  Use it like a slide hammer.  PVC isn't seating the bushing far enough. Figured I would get the correct tool for the job. 

[JimmyG]

Well, finally, after more research, they are indeed 45mm tubes.  hubcapsc showed the correct tool,(thank you), and to the rest pitching in to help

[falconbrother]

Haven't had to do anything to the Valkyrie forks..yet.  Rebuilt quite a few Harley forks and always used my homemade PVC seal driver.  Worked every time.  I think that the HD forks were a little less sophisticated than these inverted forks. 

[JimmyG]

I got the driver that hucapsc pictured above. It worked perfect. Had them suckers seated in no time at all.
Took her out for a short spin and so far no leaks, and the front end is definitely more stable again.
To you guys that use the pvc made tool, good on ya . Mine just would not do the job for me and I kept getting little plastic splinters come off the pvc and in the fork tube where I was driving the bushing in, so that's why I opted on getting the fork tool. Anyhow, all is well now with my forks.

[RonW]

Haven't had to replaced the seals on my Valk yet, so haven't tried this on the Valk forks. If you buy an extra backup washer (8, below), and place the metal washer on top of the oil seal, it's then easier to use the pvc pipe to seat the oil seal becuz the pvc will be hitting metal with the oil seal below it. Pvc material isn't that hard that it'll mar the rubber seal, but it's that the washer makes contact to almost the full the surface of the oil seal. The backup washer is just the right size. Some people even stack two pieces of pvc pipe on top of each other, and use the top pvc pipe to pile drive the pvc pipe below it.

[Bagger John - #3785]

There usually are a couple of eBay sellers listing reproduction drivers in the $50-60ish dollar region at any given time.

I found a used Honda tool for $40.

Whatever works. 

[h13man]

I turn the old seal upside down and used a cheap plastic (clear yellow head) and carefully/alternately tapped in new seal in place using the old seal as driver. Yes they are that strong or least on 1100 Spirits. A little lube on the new seal is advisable.