damper cartridge 95/96 judy's

[Sithlord]

Hi guys,,

Just wondering after pulling apart a set of judys is the damping cartridge serviceable . ?

I ask this as the ,, the damper seemed nice and smooth and fine,, then I pulled a little too hard on it and the oil dumped itself all over the workshop floor :roll:

So question is ,,, is it possible to rebuild/re-fill the damper.. ?

If so ,, does anyone have a link for re-build instructions,, and also what oil and how much would I need to use.. ?

Cheers

 

[LTS Biker]

Yes That is possible.

Whats you did happens more, the bottom comes out and oil falls out.
You'll need oil and a little bottle with a small tapered top, about 1-2mm wide, or a tapered syringe.

The easiest is an adjustable cartridge. With an allen-key you can adjust the cartridge. Unscrew it and take out the whole little adjuster-rod.

If the bottom of the cartridge is still in it, take hold the cartridge with the adjuster-Side down and tap gently with a hammer on the top of the shaft pushing the bottom out.
Take out the shaft, but leave the end in the cartridge to keep it sealed.
Fill the cartridge with oil till it is full.
Than press in the shaft and black oil seal.
Now the cartridge is about 90% full.
And from now on, you'll need patience.

Put the damper upside-down, (the adjuster-rod-opening up)
Now you'll need a tapered little bottle or syringe.
Press the oil gently in the shaft till it is full, keep the airtight pressed on the shaft and move the cartridge gently up and down.
Now you,ll see bubbles come up. Move it up and down a few time
And press in Some oil again and move the cartridge up and down again..... And so on, till there are no bubbles coming up.
Done

 

[We_are_Stevo]

...which is why they leak in the first place, and why there are several alternative options (with equally varying costs involved) for refurb'ing to be found on the web...

 

[FluffyChicken]

1995/6 has some instructions in.
1997 service guides are in the archive with. 1997 has it's own cartridge instructions guide.
Probably on LTS Biker website, sniperworks, as well
But his instructions sound a simple method

 

[LTS Biker]

Probably on LTS Biker website, sniperworks, as well
But his instructions sound a simple method

There is more to come

 

[FluffyChicken]

If I remember and can find a camera i'll get some MAG20, '94 MAG21 and '94 MAG10/'95+MAG21 internal shots so you can make up some pics like the judy and sig cutaways.
Since I happen to have a few sets apart at the moment.

 

[ishaw]

Hi Si, thought I'd post a quick note to say I've not had time to get mine apart yet - nearly made some headway today and may try again tomorrow if I manage to get the day off work. The link I sent you to the new damper set that I bought may or may not fit your forks, it depends if the internals in your forks are the same as the ones in the 97's, as I've just discovered that there is a maual in the set i bought that seems to confirm that the kit is for 97 forks. I can't see there being much difference, aside from the earlu judys had plastic bodies dampers that seemed to implode, and the later ones had metal bodied versions. With that kit you also get the spring conversion to replace the elastomers.

I need to do some refilling of a damper or two myself soon, not sure that I followed the instructions earlier in the post though, other than fill it up, and by closing the cap, some will fall out which you need to squeeze in somehow - this is where I got lost.

Ian

 

[LTS Biker]

If I remember and can find a camera i'll get some MAG20, '94 MAG21 and '94 MAG10/'95+MAG21 internal shots so you can make up some pics like the judy and sig cutaways.
Since I happen to have a few sets apart at the moment.

Nice, thanks.
it's a few hours work to make the photoshop pictures , but I think they're worth it and give a good idea of how it works.
Only a Mag is a ''bit'' more difficult.

 

[LTS Biker]

 

[ishaw]

In my attempts to sort out a set of judys I have today, I did the basics to take them apart, and as soon as I undid the allen bolts at the bottom under the damper, a whole lot of oil came pouring out. Removing the damper is simple enough, but I can't for the life of me see how to get the damper open - any ideas? I tried a test fill on a long travel version I had lying around and whilst I managed to get the top off of one end, it simply won't go back on, so help here too if anyone has had a go or has any tips.

The main reason I'm doing all of this is that I have an eko air kit for a set, and I've fitted this so have a set of internals spare. Bought some inners, outers and crown, so was having a go at making a set.

Cheers

Ian