New Thread for 636 forks /looking for new forks to put on 636
#101
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
When the thin walled lower slider flexes under braking, it becomes egg shaped. This would also stress and distort the round shape of the cast aluminum axle clamp where the two thread together. As the two parts are distorted, the threads are stressed and I can see how after many cycles of this occouring the threads would be beat to the point that the lower slider could come loose (if the stress cycles hadn't caused the lower slider to fracture first).
With the sleeve installed the lower slider can't flex (as the sleeve goes all the way down into the bottom of the axle clamp where the lower slider bottoms out) and therefore can't be distorted in shape to put stress on the axleclamp and eventually cause it to fail. The sleeve addresses both issues.
#103
Re: New Thread for 636 forks /looking for new forks to put on 636
I think initially they would have been threaded all the way down and secured with the set screw, but as they flex they just work loose over time. Good looking out Roger, as long as we can keep them tight we can keep them safe.
#105
Re: New Thread for 636 forks /looking for new forks to put on 636
got all of that bill thanks for the explanation. Seems pretty full proof to me.
what a relief this is.
your gonna be rich dude. Everyone is gonna send you there forks. I know I am.
what a relief this is.
your gonna be rich dude. Everyone is gonna send you there forks. I know I am.
#106
Re: New Thread for 636 forks /looking for new forks to put on 636
I see how that insert will reinforce the fork tube in the problem spot,but will it just move the weak point further up the slider and break above the insert,or is the problem just because of the way the fork bottoms attach and not due to a weak or brittle slider material?
#107
Re: New Thread for 636 forks /looking for new forks to put on 636
I think the smooth part of the slider cannot break, the slider breaks because it has threads which weakens the bottom.
The fork getting loose could be the first sign that the metal is starting to give. When it's just tightened, it can still go when it's tight..
I think this sleeve is good idea. It can still work loose, but it's probably lot safer for the driver.?
I think the sleeve needs to be quite thin, so it doesn't interfere with the spring. and also it's good that it has some flex so it devides the forces and doesn't create pressure point where it ends.
Also when bike is doing endo the fork is almoust completely compressed, then this sleev is inside the top part and it's solid.
The fork getting loose could be the first sign that the metal is starting to give. When it's just tightened, it can still go when it's tight..
I think this sleeve is good idea. It can still work loose, but it's probably lot safer for the driver.?
I think the sleeve needs to be quite thin, so it doesn't interfere with the spring. and also it's good that it has some flex so it devides the forces and doesn't create pressure point where it ends.
Also when bike is doing endo the fork is almoust completely compressed, then this sleev is inside the top part and it's solid.
#108
Re: New Thread for 636 forks /looking for new forks to put on 636
Originally Posted by Paul
I see how that insert will reinforce the fork tube in the problem spot,but will it just move the weak point further up the slider and break above the insert,or is the problem just because of the way the fork bottoms attach and not due to a weak or brittle slider material?
To make a short answer long the area of lower fork tube above the sleeve will not be a potential break point because it is too well reinforced by the upper slider which is being reinforced by the lower triple. The forks were braking in the first place because over the several inches that the lower tube was not shrouded by the upper during a stoppie they were distorting in shape under load due to a combination of a thin diameter lower tube (nearly two mm smaller than other inverted forks available) and a thin wall thickness. By reinforcing the lower tube we are stopping it from distorting in shape under load which was causing the axleclamp to distort and eventually compromising the threads or simply breaking the lower slider after enough stress cycles.
I think the sleeve needs to be quite thin, so it doesn't interfere with the spring. and also it's good that it has some flex so it devides the forces and doesn't create pressure point where it ends.
Also when bike is doing endo the fork is almoust completely compressed, then this sleev is inside the top part and it's solid.
Also when bike is doing endo the fork is almoust completely compressed, then this sleev is inside the top part and it's solid.
The sleeve resides underneath the damper coments. It never comes in contact with anything except the inside diameter of the lower tube, whether the fork is at rest or fully compressed. The sleeve could have actually have been made thicker but added too much unnesscessary weight and I deemed over-kill. In it's current incarnation the sleeve is still stronger than it needs to be (something I shoot for with everything Fullthrottle builds) while not adding enough weight to be significant.
#109
Re: New Thread for 636 forks /looking for new forks to put on 636
im assuming that on my spare set of forks my left bottom is starting to leakin, which means the stuctural integrity is starting to break down, and wpretty worthless to get this done correct??
if so i will just look for a 05-06 set and have them done
if so i will just look for a 05-06 set and have them done
#110
Re: New Thread for 636 forks /looking for new forks to put on 636
Sorry Paul, I failed to address the last part of your question. In regards to the way the fork bottoms/axle clamps attach, they just thread in and seal the tube at the end with an o-ring. There is a redundant set screw in the side in the KYB forks, but otherwise they are the same across the board between KYB and Showa. I think the only reason you see these forks failing and not others is because as I mentioned, these forks are the longest available and they use the thinnest diameter lower slider with the thinnest wall available. Other forks (like the 929/954) have a lower tube with nearly as thin of a side wall, but the the diameter of the lower tube is larger which adds alot of strength and the length is shorter which reduces the stress that it has to handle.
#111
Re: New Thread for 636 forks /looking for new forks to put on 636
Sorry Paul, I failed to address the last part of your question. In regards to the way the fork bottoms/axle clamps attach, they just thread in and seal the tube at the end with an o-ring. There is a redundant set screw in the side in the KYB forks, but otherwise they are the same across the board between KYB and Showa. I think the only reason you see these forks failing and not others is because as I mentioned, these forks are the longest available and they use the thinnest diameter lower slider with the thinnest wall available. Other forks (like the 929/954) have a lower tube with nearly as thin of a side wall, but the the diameter of the lower tube is larger which adds alot of strength and the length is shorter which reduces the stress that it has to handle.
#112
Re: New Thread for 636 forks /looking for new forks to put on 636
Another option would be to replace the lower slider and axleclamp with one from the dealership. I called on it, retail is nearly $400 on that part. It would be a close race between which is cheapest, that part or a set of used forks.
#113
Re: New Thread for 636 forks /looking for new forks to put on 636
Gotcha I didn't realize that the insert extends that far up that it actually rienforces the whole lower slider not just the fork bottoms.That should make for one hell of a set of forks!Definately wont have to worry about breaking that!Nice job and thank's for the response.:YEAH
#114
Re: New Thread for 636 forks /looking for new forks to put on 636
yea it would be close..i think i can find a set of forks for a bit cheaper...and see what cost is on that part form my dealer...either way i am goin to be sending you a set of forks on the near future
#115
Re: New Thread for 636 forks /looking for new forks to put on 636
Are the UK and European bikes made in the same factory? as iv never heard anyone snapping them over here!?! just a thought as some of the guys have been using them in europe since 03!
Anyone know if they are all japan imports or assembled locally as your 03 has a different model name to mine!?
Anyone know if they are all japan imports or assembled locally as your 03 has a different model name to mine!?
#116
Re: New Thread for 636 forks /looking for new forks to put on 636
what if you were to take apart the stock forks before getting them too far into stunting and add some thread lock to the lower section versus doing this right away, i took my front wheel off just to check that set screw and mine was corroded in there and wasn't moving at all, but at the same time i have been thinking a lot about just getting a set of 07 zx6r forks cuz i dont want to take the chance, but maybe instead of doing that it'd be cheaper to do this to my stock 03 636 forks because they only have 7K miles on um and basically all street stuntin miles for past 1K or so, before that i think it was rode by a kid that couldn't get the front wheel up let alone stunt it
#117
Re: New Thread for 636 forks /looking for new forks to put on 636
awesome , one more thing I m wondering 05 R1 will just work on 636 triples tree to just slide in and tight it up ?
of course it has to be with wheel , rotors and brake caliper.
of course it has to be with wheel , rotors and brake caliper.
#118
Re: New Thread for 636 forks /looking for new forks to put on 636
Are the UK and European bikes made in the same factory? as iv never heard anyone snapping them over here!?! just a thought as some of the guys have been using them in europe since 03!
Anyone know if they are all japan imports or assembled locally as your 03 has a different model name to mine!?
Anyone know if they are all japan imports or assembled locally as your 03 has a different model name to mine!?
#119
Re: New Thread for 636 forks /looking for new forks to put on 636
i had my 04 forks for 2 seasons didnt snap.................
can someone post a pic of were they snap and is the problem that the threading strips loose???
can someone post a pic of were they snap and is the problem that the threading strips loose???
Last edited by DURTY; 11-13-2007 at 01:49 AM.
#120
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
durty every thing you asked for has been covered in this thread go back and start at the beginning