Fork Cap Installation - Street and a few Dirt Bikes
(XR400, CR85 & RM85s)
or
"How to Make the Adjusters Have the Right Amount of Clicks"

 

There are two basic types of adjusting screws on street bike fork caps:

1) One that stops when you turn it in and

2) one that doesn't.

To see which type you have you will need to have the cap off the damping rod. Back out the adjusting screw (counterclockwise) all the way until it stops. Attempt to screw it in 6 turns, (count turns as not all caps have clicks). If it stopped turning at 4 or 5 turns you have the type where the adjusting screw stops. If you are still turning and a tiny ball bearing and spring fall out, you've gone way too far. If this happens look in the waste oil pan you have sitting under the bench in the corner as that is where most things you drop end up.

With both types of caps the procedure is almost the same. 

Note: Click on the images to enlarge.

Supplies 
 
USF-05 Fork Oil - extremely slippery
Contact Cleaner - or other good, clean solvent
Fork Springs (likely - check the Product Search for rate recommendations)

Tools 
 
These are some special tools you may want.
 
   or
TMVJ 065 Vise Jaws mounted on a Vise - suggested
 

INSTALL THE FORK CAP
HOW TO CREATE THE CORRECT NUMBER OF CLICKS
 
FA19- Make sure the Rebound Adjusting Screw is backed out all the way then screw it in 20 clicks. This step is important in setting the fork cap height as well as the proper number of clicks of adjustment.
 
If there are no "clicks" back out the Adjusting Screw 5 turns.

FA20- Tighten the Fork Spring Compressor but make sure you stop before the tool hits the top of the fork tube. Tightening the tool is best accomplished with an electric drill with a socket or a speed handle.
 
Do not use an impact or it will destroy the tool.

FA21- Once the fork is compressed enough, extend the damping rod and remove the Bleeding Tool. 
 
Check that the Jam Nut is on all the way. This makes sure it is out of the way for now.

FA22- Install the Fork Cap. Make sure the Fork Spring Preload Adjuster is backed out all the way.

FA23- Screw it down until it gently seats the rebound needle.
 
When the Cap is being screwed on to the Damping Rod the Rebound Adjuster Screw eventually contacts the Rebound Adjuster Rod. As the Cap continues to be screwed on, the Rebound Needle is being compressed until it eventually contacts the Rebound Needle Seat.
 
If you tighten it with force it will jam the Needle into the Seat and damage this point of contact... so be gentle.

FA24- Bring the jam nut up against the fork cap.

FA25- Back out the adjuster a few clicks to give the Needle clearance from the Seat while you...

FA26- tighten the Jam Nut.
 
Check the number of Rebound Adjuster clicks that are available. There should be close to 20 clicks (or 5 turns) as that is what the procedure we use creates. If it is more than 2 clicks different than that remove the cap and repeat the procedure.

FA27- Unscrew the Fork Spring Compressor Tool and tighten the Cap.