October 17, 201312 yr I have a problem with fork sag on my 1997 jtx 250, as in the static sag is way too excessive, somewhere in the region of an inch! I have heard that I can just make a longer preload spacer out of some 1" schedule 40 PVC pipe, but I have a concern... I don't think I will be able to remove the top damping adjuster of each fork leg to remove this spacer because the Allen bolts holding them in look rounded off. So, is it possible to make up a 10mm spacer out of this PVC pipe, make a slit down the side of it and put it on top of the original spacer that way? My reasoning is that once the forks are assembled again the fork tube will keep it from ever coming off. Sound feasible?
October 17, 201312 yr If the forks are the same as my 99 321 then the allen bolts aren't involved in changing a spacer, do you have a pic? See my recent thread regarding a similar problem that turned out to be a broken spring. http://www.trialscentral.com/forums/topic/46109-1999-321-fork-cap-removal-sag-preload/
October 17, 201312 yr Author No pics I'm afraid. I have had them apart to change the fork oil seals and holders in each leg, I was hoping by sorting the leaky forks that the sag might be better but this is not the case. So can I not slide in a new 10mm spacer using the slit down one side method without draining the oil again? I thought I might be able to undo the top nut and compress the forks to reveal the spring...?
October 17, 201312 yr I tried to reply on the other day but the post got lost. Just a plastic spacer off a water pipe will do. Somewhere from 10-20mm. I would just pull the top off the springs. It can be done without everything coming apart. The slit idea leaves too much room for failure.
October 17, 201312 yr Author Can you elaborate on the point about not having to take everything apart please? Just don't want to buy oil again so soon is all if it involves draining it.
October 17, 201312 yr You are going to remove the forks. But just remove the caps from the tube and slide the tube just far enough to add the spacer. Not draining the oil might be hard. You could drain it out the top and re-use.
October 17, 201312 yr Author How do you remove the caps then? Is there a locking but under the big nut and adjuster on top of the fork? Sorry, I really need pics to grasps things like this, that or videos.
October 17, 201312 yr You need to undo the triple trees or fork leg clamps to be able,to remove or adust the preload spacer,or at least the top clamps to be able to release the large top caps,which in turn allows the springs to pop through,then if you get that far,compress the spring to make visable the lock nut no 19 in diagram,then slacken that off just a little,then try and grip the same threaded rod futher down while unscrewing no5,which will enable you to remove or replace the spacer tubes.Hope this makes sence. Edited October 17, 201312 yr by bilks
October 17, 201312 yr Author Cheers for that, makes it a lot clearer! Is no4 on show on the underside of no5 then?
October 17, 201312 yr You could unscrew using the large cap screw,with a large socket,the spacer tube fits betwwen no 5 and the large spacer washer just above the spring,but it should unscrew by hand,no need to touch anything else above 5. Edited October 17, 201312 yr by bilks
October 17, 201312 yr Author Gotcha, will tackle that at the weekend, just need to find some suitable tubing. Thanks a lot bud!
October 18, 201312 yr Might be of some help in future http://www.trialspartsusa.com/manuals/1997JTXPartsBook.pdf Edited October 18, 201312 yr by bilks
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