New Thread for 636 forks /looking for new forks to put on 636
11-07-2007, 04:45 PM
#81
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Join Date: Jun 2004
Location: NW Indiana
Age: 45
Posts: 553
Re: New Thread for 636 forks /looking for new forks to put on 636
John and Roger, we must think alike. Nasty left his 636 at my shop for the week and I was really interested in this problem. About 4 years ago I made a 954 front end fit a 2003 sportster 883R. I only used the fork legs and retained the factory front wheel and fender. In order to do this I made billet axle clamps (complete with the proper damping adjuster) and used radial calipers as back then they were just coming out on sportbikes and were kind of a big deal. Naturally I had to make upper and lower clamps for this all to work but that's besides the point. In doing so I got to know my way around the inside of various forks pretty well because the 954's were too short so I ended up using other KYB or Showa forks before I ended up with a pair that fit my needs.
So anyway, short story long, being interested in this problem I disassembled Nasty's forks and found that there is indeed room for a steel sleeve to prevent the lowers from breaking. I installed a cnc turned and ground sleeve and it worked out great. It goes an inch and a half down into the axle clamp and nearly 4 inches up into the top slider (that's with the fork tube off the bike). I used a 3/16 side wall to ensure it would be stronger than it has to be, but didn't want to go any thicker than that with an eye towards weight (the sleeve adds 2.3 pounds to the assembled fork). I've been working on this since he'd left his bike here on Monday but it's been worth it as I believe this solution will completely eliminate the incidence of a lower tube snapping and is much more practical than replacing an entire front end.
I hope you guys don't think I scooped you, I initially began disassembling the front end with the idea of turning and grinding a heavier lower slider, but due to the limited clearance at the top of the tube (due to the damping components and the bottom of the spring) a precision sleeve just made more sense.
I'm offering this service to the public here:
http://www.fullthrottleinc.net/store...roducts_id/198
So anyway, short story long, being interested in this problem I disassembled Nasty's forks and found that there is indeed room for a steel sleeve to prevent the lowers from breaking. I installed a cnc turned and ground sleeve and it worked out great. It goes an inch and a half down into the axle clamp and nearly 4 inches up into the top slider (that's with the fork tube off the bike). I used a 3/16 side wall to ensure it would be stronger than it has to be, but didn't want to go any thicker than that with an eye towards weight (the sleeve adds 2.3 pounds to the assembled fork). I've been working on this since he'd left his bike here on Monday but it's been worth it as I believe this solution will completely eliminate the incidence of a lower tube snapping and is much more practical than replacing an entire front end.
I hope you guys don't think I scooped you, I initially began disassembling the front end with the idea of turning and grinding a heavier lower slider, but due to the limited clearance at the top of the tube (due to the damping components and the bottom of the spring) a precision sleeve just made more sense.
I'm offering this service to the public here:
http://www.fullthrottleinc.net/store...roducts_id/198
11-07-2007, 04:59 PM
#84
Registered User
Join Date: Jun 2004
Location: NW Indiana
Age: 45
Posts: 553
Re: New Thread for 636 forks /looking for new forks to put on 636
I forgot to mention, if someone has a leaky seal I'll replace them both for an additonal $25 while I'm in there. I would just do it anyway but with so many of these bikes only being a few years old an low miles it doesn't make sense to charge everyone for seals considering you don't damage them durning sleeving and most don't need them. Then again, if you do need them, this is a good way to hit two birds with one stone.
11-07-2007, 04:59 PM
#85
I Enjoy Posting At StuntLife!
Join Date: Oct 2002
Location: Clearwater,Florida
Age: 43
Posts: 2,615
Re: New Thread for 636 forks /looking for new forks to put on 636
so basically its reinforcement of the tube.....thank you bill when i go to rebulid my bike....this is a must have mod:YEAH
11-07-2007, 05:02 PM
#86
Registered User
Join Date: Oct 2002
Location: Marietta, GA
Age: 44
Posts: 7,019
Re: New Thread for 636 forks /looking for new forks to put on 636
John and Roger, we must think alike. Nasty left his 636 at my shop for the week and I was really interested in this problem. About 4 years ago I made a 954 front end fit a 2003 sportster 883R. I only used the fork legs and retained the factory front wheel and fender. In order to do this I made billet axle clamps (complete with the proper damping adjuster) and used radial calipers as back then they were just coming out on sportbikes and were kind of a big deal. Naturally I had to make upper and lower clamps for this all to work but that's besides the point. In doing so I got to know my way around the inside of various forks pretty well because the 954's were too short so I ended up using other KYB or Showa forks before I ended up with a pair that fit my needs.
So anyway, short story long, being interested in this problem I disassembled Nasty's forks and found that there is indeed room for a steel sleeve to prevent the lowers from breaking. I installed a cnc turned and ground sleeve and it worked out great. It goes an inch and a half down into the axle clamp and nearly 4 inches up into the top slider (that's with the fork tube off the bike). I used a 3/16 side wall to ensure it would be stronger than it has to be, but didn't want to go any thicker than that with an eye towards weight (the sleeve adds 2.3 pounds to the assembled fork). I've been working on this since he'd left his bike here on Monday but it's been worth it as I believe this solution will completely eliminate the incidence of a lower tube snapping and is much more practical than replacing an entire front end.
I hope you guys don't think I scooped you, I initially began disassembling the front end with the idea of turning and grinding a heavier lower slider, but due to the limited clearance at the top of the tube (due to the damping components and the bottom of the spring) a precision sleeve just made more sense.
I'm offering this service to the public here:
http://www.fullthrottleinc.net/store...roducts_id/198
So anyway, short story long, being interested in this problem I disassembled Nasty's forks and found that there is indeed room for a steel sleeve to prevent the lowers from breaking. I installed a cnc turned and ground sleeve and it worked out great. It goes an inch and a half down into the axle clamp and nearly 4 inches up into the top slider (that's with the fork tube off the bike). I used a 3/16 side wall to ensure it would be stronger than it has to be, but didn't want to go any thicker than that with an eye towards weight (the sleeve adds 2.3 pounds to the assembled fork). I've been working on this since he'd left his bike here on Monday but it's been worth it as I believe this solution will completely eliminate the incidence of a lower tube snapping and is much more practical than replacing an entire front end.
I hope you guys don't think I scooped you, I initially began disassembling the front end with the idea of turning and grinding a heavier lower slider, but due to the limited clearance at the top of the tube (due to the damping components and the bottom of the spring) a precision sleeve just made more sense.
I'm offering this service to the public here:
http://www.fullthrottleinc.net/store...roducts_id/198
Like i said in the other thread! SIIIIIIIIIIIIICK!
Way to be on top of things FAST bill!!!
I'll be talking to you very soon!!!
Bill and Fullthrottleinc.com for PRES.!!!
Last edited by John LegionST; 11-07-2007 at 05:04 PM.
11-07-2007, 05:02 PM
#87
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Join Date: Jun 2004
Location: NW Indiana
Age: 45
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11-07-2007, 05:05 PM
#88
also known as OMR
Join Date: Jul 2006
Location: OMR INDUSTRIES in west palm beach florida
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11-07-2007, 05:20 PM
#91
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Join Date: Oct 2002
Location: Marietta, GA
Age: 44
Posts: 7,019
Re: New Thread for 636 forks /looking for new forks to put on 636
sucks he is far away, but still MORE than worth it!!!
11-07-2007, 05:36 PM
#93
Registered User
Join Date: Jun 2004
Location: NW Indiana
Age: 45
Posts: 553
Re: New Thread for 636 forks /looking for new forks to put on 636
http://www.fullthrottleinc.net/store...roducts_id/198
If you read the description, you'll note that Fullthrottleinc pays for shipping of the container to your door to pick up your forks and to the shop to rebuild them. All you pay for is shipping after they are rebuilt regardless of location. You'll still pay the same price as everyone else, you'll just pay more to have them shipped back.
11-07-2007, 06:11 PM
#94
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Join Date: Apr 2003
Location: J.ville, N.Carolina
Age: 41
Posts: 2,965
Re: New Thread for 636 forks /looking for new forks to put on 636
That it is!!! very worth it. If I coulda spent the money to prevent my fork snappin incident I would have FOR SURE!!!
11-07-2007, 06:42 PM
#95
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Join Date: Sep 2003
Location: bristol, patheticut
Posts: 1,277
Re: New Thread for 636 forks /looking for new forks to put on 636
props to everyone who has contrubuted to this thread.
I know roger woulda had something designed if bill didn't beat him to it.
Bill you are my hero. I'm have been so bummed out the past few days over this. I was about to say screw it and sell the 3 636's I own and switch to honda.
Thank you so much for this modification.
I read what john legion wrote" Is the sleeve going to stop from the fork tube from seperating from the lower fork leg? or is this just going to prevent the tube from breaking in half?
I know on the 03/04 tubes both situations have happend.
dammit I wish I was online earlier I woulda beat that other guy and had a set of 05/06 forks in the mail today to be the first set.
I was going to list all of my 636 forks on ebay tonight thank go I read the awsome news.
Ok now i'm motivated to go ride in the cold tonight and get crazy
i'll be in touch soon bill:YEAH
I know roger woulda had something designed if bill didn't beat him to it.
Bill you are my hero. I'm have been so bummed out the past few days over this. I was about to say screw it and sell the 3 636's I own and switch to honda.
Thank you so much for this modification.
I read what john legion wrote" Is the sleeve going to stop from the fork tube from seperating from the lower fork leg? or is this just going to prevent the tube from breaking in half?
I know on the 03/04 tubes both situations have happend.
dammit I wish I was online earlier I woulda beat that other guy and had a set of 05/06 forks in the mail today to be the first set.
I was going to list all of my 636 forks on ebay tonight thank go I read the awsome news.
Ok now i'm motivated to go ride in the cold tonight and get crazy
i'll be in touch soon bill:YEAH
11-07-2007, 06:49 PM
#96
Registered User
Join Date: Jun 2006
Location: B'ham AL
Age: 41
Posts: 3,016
Re: New Thread for 636 forks /looking for new forks to put on 636
No worries Brits! (or anywhere else for that matter)
http://www.fullthrottleinc.net/store...roducts_id/198
If you read the description, you'll note that Fullthrottleinc pays for shipping of the container to your door to pick up your forks and to the shop to rebuild them. All you pay for is shipping after they are rebuilt regardless of location. You'll still pay the same price as everyone else, you'll just pay more to have them shipped back.
http://www.fullthrottleinc.net/store...roducts_id/198
If you read the description, you'll note that Fullthrottleinc pays for shipping of the container to your door to pick up your forks and to the shop to rebuild them. All you pay for is shipping after they are rebuilt regardless of location. You'll still pay the same price as everyone else, you'll just pay more to have them shipped back.
You listed 03-04 does this work on 05-06 forks as well? I got a leaking fork seal. might as well have this done at the same time
11-07-2007, 06:58 PM
#97
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Join Date: Jun 2004
Location: NW Indiana
Age: 45
Posts: 553
11-07-2007, 07:08 PM
#100
also known as OMR
Join Date: Jul 2006
Location: OMR INDUSTRIES in west palm beach florida
Posts: 79,288
Re: New Thread for 636 forks /looking for new forks to put on 636
I read what john legion wrote" Is the sleeve going to stop from the fork tube from seperating from the lower fork leg? or is this just going to prevent the tube from breaking in half?
