xb12r 04 front fork rebuild

[gadgetkeith]

hi there im new to this forum have read a lot of posts etc
and there seems to be a lot of great advice given out here and there
im going to have a look at the front forks on a friends bike does anyone know oil quantity per leg ie showa 43mm inverted forks
as mentioned in heading its an 04 1200 firebolt
thanks in advance keith

 

[konarider94]

im pretty positive the 04's have 41mm forks. 1 quart of oil will be enough for both. I have a 2004 xb12s and i rebuilt the forks about a month ago and im 100% sure i have 41mm forks. i think the firebolts are the same but ive been wrong before.

 

[konarider94]

if you have any other questions feel free to ask. there is a good video here. they are off of a ducati in the video but the forks are the same. i would like to note that the damper rod assembly does NOT have to come out to change the seals and bushings. This is the socket screw in the bottom of the fork.


disassembly part 1
disassembly part 2
reassembly part 1
reassembly part 2

 

[gadgetkeith]

hi thanks for the great response
looking at forks right now they seem ok before i delve deeper
one quick question front rotor inserts should there be slight amount of play or should the be an interferance fit ie snug but no play or movment
the reason i ask is because the main reason for lookin at it is a slight knocking while riding
thanks keith

 

[konarider94]

those drive bushings are considered a wear item so they may need to be replaced. the rotor shouldnt feel loose when you try to move it by hand.

is the knocking worse when you apply brakes?

could be wheel bearings maybe. have you picked the front end of the bike off the ground and tried to move things to see if anything felt awkward.

 

[Stevenc150]

Not sure if this is what you were asking, but the front rotor is supposed to have some movement to it - referred to as a "floating" rotor.

 

[gadgetkeith]

hi there
tried all things out
checking for play
in
head set
wheel bearing
brake caliper mount
tripple trees
the only thing i can find is very slight play in rotor mount fittings
the little squarish blocks that slot into the rotor show slight wear on one side only
tried switching 3 of the 6 around to see if that would eliminate some of the play
which it did very slightly but not completely
should these be a very snug fit with no play at all
are new replacments a tight fit as im thinking this is the cause of what he is feeling whilst riding
doesnt seem to be any play or other faults that i can find
also not mentioned i do have a fair mechanical history over last 20 or so years with motorcycles and cars etc
the main thing is local stealerships dont seem to be of much help all they seem to want is to take ya money and do the job for ya they dont want to give any advice
thanks keith

 

[konarider94]

I dont know. I havent had to change mine. Ive never even had the rotor off. My expertise was in the forks.

 

[gadgetkeith]

hi there
my friend has ordered the rotor drive bushings
i will repost in a couple of days the result
hope this does the trick
we are going to change his fork oil aswell just because he wants to so will let you know the results
thanks for all the advise
keith