front suspension issue/problem on my 2006

[Daytona_Mike]

I just remove the bottom bolt. I use a  broom handle to hold the emulsion tube still when putting it back together. The only tool I need is an air impact tool to remove the bolt. Then some brake cleaner and compressed air to make sure it is all out and  clean in there.
Better yet, you need to learn how to remove the fork tubes anyway as it is easy to do.

[julianop]

Thanks for these fresh replies. I'm going to address this issue in the spring, but I'm working on a second set of wheels so I don't have to survive without a ride while I do the work 

[VirginiaJim]

How about those pics on the tab fix?

[Gitbox]

To you guys that added drain holes to your forks, how did you deburr the holes? I had a heck of time deburring the holes I had to drill in the emulsion tubes for the cartridge emulator upgrade.


(great upgrade, by the way)

[Strawboss]

I just used a REAL big drill bit  with my fingers.

[timsatx]

To you guys that added drain holes to your forks, how did you deburr the holes? I had a heck of time deburring the holes I had to drill in the emulsion tube for the cartridge emulator upgrade.


(great upgrade, by the way)

Are you talking about the inside or outside?

[Gitbox]

The inside. (duh    )


I was thinking those little burrs from the drilling process might break off at some point and mess up the fork works. Call me anal.


I asked a machinist about deburring the emulsion tube holes (on the inside) and he recommended, as he called it, a Kentucky reamer - a slot in a rod with sandpaper in it. Attach it to a drill and spin away until smooth. I suppose I could've done the same thing with the drain holes.

[timsatx]

I think the issue of deburring the inside can be removed if you use the following method. Use a small bit as a pilot bit to keep it from walking. The second bit should be a couple of sizes smaller than the final size. Then use the final size. Usually the burr comes from using  a bit to remove a lot of material. As an example, for an 8-32, the recommendation (in the chart I have) for 75% threads on aluminum should be a #29 bit (.1360). I would use as my second drill bit either a #31 (.1200) or a #32 (.1160). And be sure to let the bit do the work, do not try and shove it thru.

[K-woppa]

How about those pics on the tab fix?

If it helps at all, I have a thread over on ex500.com where I show how I did a bunch of small plastic repairs on my Connie using West System Gflex epoxy.
 http://www.ex-500.com/index.php/topic,54361.0.html
You would have to make yourself a member of the forum to read it, but it you're interested in plastic repairs it could be helpful. 

[Alex_V]

Was the bike ever down?

It's a wild guess, but forks binding can make them feel stiff. That is what is going on a C14 project that I am fixing. Sometimes loosening all bolts: triples, axle and re-tightening will reset the forks back to straight, sometimes parts need to be replaced. This often happens on race bikes that kissed the pavement.

Just pointing a finger in the sky for another probable cause.

[Nosmo]

There are many types of internal deburring tools available, not too expensive.

http://www.cogsdill.com/products/deburring/

http://www.mscdirect.com/browse/Abrasives/Deburring-Tools?navid=12100012

http://www.royalprod.com/product.cfm?catID=7

http://www.noga.com/nogaCategories.php?catID=deb&agent_camp=4377001&agent_bann=4380001&gclid=CNnlhZv4i7sCFUiDfgodKxgA6w

[datsaxman@hotmail.com]

Yes, I did NOT do anything fancy to deburr the insides of the holes, but DID use four bits
to generate small chips.  Flush, flush, flush, greased the tap, cleaned it several times and regreased, etc.  Plus there was the (patent pending) leaking seal to continue to purge the chips while I was learning that the tubes would need a flat for the washer to seat. 

Mike, OP may already "know how to pull the fork tubes", but may want to NEVER have to do that job.

That was me.  "Learned how" about 45 years ago, myself.  Not excited about pulling the whole front end apart if I can avoid it, really. 

saxman