RJ The Bike Guy
Suntour XCT Fork Service - Disassemble/Clean/Lube/Re-assemble
updated
FYI, I called them as a regular customer. I did not tell them I was RJ The Bike Guy, or mention anything about having a YouTube channel.
Here is the recall notice for these forks:
cpsc.gov/Recalls/1995/cpsc-and-rock-shox-announce-recall-of-1992-mag-20-and-mag-30-suspension-fork-crowns
This is the number I called:
800-346-2928
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http://bit.ly/ForkOverhauls
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I had never heard of this, but a viewer turned me onto it. After some research found it was a thing. So I tried it, and thought it was a great idea. Still learning new stuff after all these years.
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The Park Tool DAG 2.2 is a really nice tool, but it is kind of expensive. So I have a video shwoing how to make a cheaper home made version of of the tool here - How To Make A Derailleur Hanger Alignment Gauge Tool: youtube.com/watch?v=sWdO4dnu18g
But if you want, the Park Tool DAG 2.2 is here:
amazon.com/exec/obidos/ASIN/B010T6L22E/ref=nosim/youtube25-20
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How To Make An Extra Long Hex Socket Tool:
youtube.com/watch?v=j8oGZr-OSRU
* Use grease made for forks. I use Slickoleum which is also sold under the name Slick Honey. You can also use SRAM Butter or Judy Butter. If the fork uses oil, use the proper fork oil. Use of a grease/oil not made specifically for forks can damage the plastic/polyurethane parts, or otherwise leave the fork not working properly.
Slickoleum 15oz:
amazon.com/exec/obidos/ASIN/B07CKKTNCS/ref=nosim/youtube25-20
Slickoleum 4oz:
amazon.com/exec/obidos/ASIN/B07RXDMNSH/ref=nosim/youtube25-20
Suntour fork cap tools:
amazon.com/exec/obidos/ASIN/B089SNM9RK/ref=nosim/youtube25-20
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http://bit.ly/ForkOverhauls
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So if you need a tool and don't have it, and can't buy it, look at making the tool you need. Yeah, I spent around $11 to make the tool, but now I will be able to do my fork overhaul, and will still have the tool if I need it again.
No, using a longer extension would not have helped. The 5mm bolt was in a deeply recessed hole.
Yes, I could have left the shaft longer, but the longer the shaft, the more it will twist under torque. So I only made it a little longer than I knew I would need.
Tekton Extra Long Socket Set:
amazon.com/exec/obidos/ASIN/B001NT2LK4/ref=nosim/youtube25-20
▶ Homemade Bike Tools: http://bit.ly/DIYBikeTools
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About the only new parts that went into the bike were the chain, cables, and housings. The other parts were used that I had in my parts boxes.
Evapo-Rust (rust remover):
amazon.com/exec/obidos/ASIN/B00M0TLQ66/ref=nosim/youtube25-20
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The replacement bearings cost $6.69 + tax for a total of $7.23 for a four pack on Amazon. They are probably Chinese made, but most of the bearings I was seeing seemed to be made in China. I would have liked to have gotten some nice made in Japan bearings, but I was not finding any in this size. I am sure they are out there.
Not all bottom brackets have sealed cartridge bearings. Here is a rebuild of a bottom bracket that has ball bearings:
youtube.com/watch?v=lar7mIMmTRE
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Service Manual for Avid BB5 & BB7:
sram.com/globalassets/document-hierarchy/service-manuals/sram-mtb/brakes/gen.0000000003513-rev-b-2012-bb7--bb5-service-manual-english
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Answer Manitou 1 Rebuild:
youtube.com/watch?v=TVPdNUZy1S8
Slickoleum 15oz:
amazon.com/exec/obidos/ASIN/B07CKKTNCS/ref=nosim/youtube25-20
Slickoleum 4oz:
amazon.com/exec/obidos/ASIN/B07RXDMNSH/ref=nosim/youtube25-20
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http://bit.ly/ForkOverhauls
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I bought this Specialized Rockhopper Comp a few years ago. It was in rough shape, but it had promise. What I liked about it was the frame & forks and had disc brake mounts, and the wheels were set up to mount disc brake rotors. It was screaming for this upgrade. I finally got around to doing it. The disc brake calipers I installed were Avid BB5's. The rotors were 160mm.
Some people have asked me about the locking adjustable wrench I used in the video. The wrench is made by Craftsman:
amazon.com/exec/obidos/ASIN/B00X0IYM08/ref=nosim/youtube25-20
Though there are other brands.
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I picked up this Marin mountain bike cheap because the fork was dead (bottomed out). The elastomers were toast. I ordered a rebuild kit for about $60. As I disassembled the fork, I found the old elastomers had turned to goo, and solidified inside. I warmed up the fork to turn them back to goo, and was able to pull them apart. I used heat to remove a lot of the elastomer goo, and cleaned up the rest of it with acetone. Once I got the elastomer goo cleaned up, then rest was pretty easy.
Slickoleum 15oz:
amazon.com/exec/obidos/ASIN/B07CKKTNCS/ref=nosim/youtube25-20
Slickoleum 4oz:
amazon.com/exec/obidos/ASIN/B07RXDMNSH/ref=nosim/youtube25-20
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http://bit.ly/ForkOverhauls
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Manitou Answer 1 Fork Rebuild/Overhaul:
youtube.com/watch?v=TVPdNUZy1S8
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First ride on a recumbent bike:
youtube.com/watch?v=THjOL4k-s3o
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Thanks to the guys at R Community Bikes!
rcommunitybikes.org
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The bike is a Trek 3700 mountain bike.
Seatpost Size - From Wrong To Right:
youtube.com/watch?v=E4YHKdqwnFY
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The fork model is a SR Suntour M2015.
The fork cap tool I mad was very similar to this, except it had 12 teeth, and was a larger diameter:
youtube.com/watch?v=tABGvESjL4o
How To Install Lizard Skins Fork Boots Replacements:
youtube.com/watch?v=2or_Je4fRz4
* Use grease made for forks. I use Slickoleum which is also sold under the name Slick Honey. You can also use SRAM Butter or Judy Butter. If the fork uses oil, use the proper fork oil. Use of a grease/oil not made specifically for forks can damage the plastic/polyurethane parts, or otherwise leave the fork not working properly.
If you have a different brand model fork, check out some of my other fork overhaul videos here http://bit.ly/ForkOverhauls
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The bike is a 10 speed. The 63cm frame is lugless steel. I believe the bike is from the early to mid 70s. The bottom bracket seems to be sealed bearings. The derailleurs are a Shimano Crane in the rear, and a Shimano Titlist on the front. The wheels at 27" with Campagnolo high flange hubs, and Rigida clincher rims. The leather saddle is an Ideale Speciale Competition 90. The seatpost measures 26.8mm. The stem quill is 22.2mm, so not French. The bike as is weighs about 25.2lbs. The tires (maybe not original) are a Schwinn 250 Super Record, and a Schwinn HP Le Tour.
ANSWER: It is apparently a Viscount Aerospace. It originally came with a cast aluminum "death fork" that was know to fail. THIS BIKE HAS A STEEL FORK, so apparently the original fork was replaced. The "V" logo on the components is for Viscount.
And I think it IS the original paint. The blue on the seat tube normally has decals over the ends of the blue paint.
Sheldon Brown wrote about the bike here:
sheldonbrown.com/lambert.html
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As a safety precaution, I used gloves, and had my garage door open for ventilation. Also be careful around open flame as gasoline is flammable.
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The bike is a 2000 Trek 6000. The hub is a Shimano FH-C201.
Freewheel vs Cassette:
youtube.com/watch?v=qcgz3-XyNkI
How To Fix A Sticky Freewheel:
youtube.com/watch?v=lVc1r2giqPc
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Check here for various SRAM Grip Shift cable install videos:
youtube.com/playlist?list=PLxO5aF0sensjdXh9ashh5FDy0U2D3uAQk
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* Use grease made for forks. I use Slickoleum which is also sold under the name Slick Honey. You can also use SRAM Butter or Judy Butter. If the fork uses oil, use the proper fork oil. Use of a grease/oil not made specifically for forks can damage the plastic/polyurethane parts, or otherwise leave the fork not working properly.
Slickoleum 15oz:
amazon.com/exec/obidos/ASIN/B07CKKTNCS/ref=nosim/youtube25-20
Slickoleum 4oz:
amazon.com/exec/obidos/ASIN/B07RXDMNSH/ref=nosim/youtube25-20
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http://bit.ly/ForkOverhauls
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These are the 2000 model of RockShox Jett forks. The 2001 model were recalled (The serial number will start with 01). cpsc.gov/Recalls/2000/cpsc-rockshox-inc-announce-recall-of-bicycle-forks
* Use grease made for forks. I use Slickoleum which is also sold under the name Slick Honey. You can also use SRAM Butter or Judy Butter. If the fork uses oil, use the proper fork oil. Use of a grease/oil not made specifically for forks can damage the plastic/polyurethane parts, or otherwise leave the fork not working properly.
Slickoleum 15oz:
amazon.com/exec/obidos/ASIN/B07CKKTNCS/ref=nosim/youtube25-20
Slickoleum 4oz:
amazon.com/exec/obidos/ASIN/B07RXDMNSH/ref=nosim/youtube25-20
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* Use grease made for forks. I use Slickoleum which is also sold under the name Slick Honey. You can also use SRAM Butter or Judy Butter. If the fork uses oil, use the proper fork oil. Use of a grease/oil not made specifically for forks can damage the plastic/polyurethane parts, or otherwise leave the fork not working properly.
If you have a different brand model fork, check out some of my other fork overhaul videos here http://bit.ly/ForkOverhauls
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And no, leaving the wax on to "soak" into the paint does not work. The Carnuba wax only effects the surface of the paint.
Things like gasoline, acetone, carburetor cleaner, or other solvents, can damage the factory paint.
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The bikes I bought were:
2004 Trek 1500 road bike.
2001 Cannondale F600 mountain bike.
2000 Specialized Hardrock mountain bike.
1994 Diamondback Axis TR mountain bike.
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There are different versions of XCT forks. This is an SF10. If yours has a lockout, you have a different version. You might check out my video overhauling an XCR fork that has a lockout:
youtube.com/watch?v=BUgt96qfV68
The part number for the plastic sleeve is FEE460-10.
Suntour XCT Fork Service:
youtube.com/watch?v=BIJPeh-D8D4
* Use grease made for forks. I use Slickoleum which is also sold under the name Slick Honey. You can also use SRAM Butter or Judy Butter. If the fork uses oil, use the proper fork oil. Use of a grease/oil not made specifically for forks can damage the plastic/polyurethane parts, or otherwise leave the fork not working properly.
Slickoleum 15oz:
amazon.com/exec/obidos/ASIN/B07CKKTNCS/ref=nosim/youtube25-20
Slickoleum 4oz:
amazon.com/exec/obidos/ASIN/B07RXDMNSH/ref=nosim/youtube25-20
Suntour fork cap tools:
amazon.com/exec/obidos/ASIN/B089SNM9RK/ref=nosim/youtube25-20
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Most front hubs use ten 3/16" balls on each side; Most rear hubs use nine 1/4" on each side.
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* NO!!! The chain stay cannot just be easily welded. The whole tube was expanded and deformed. The split is just the most visible part of the damage! The frame would be unsafe. An experienced frame builder could probably replace the stay, but it would cost more than the bike is worth.
* I don't care that I didn't pronounce Allez the correct French way. If I pronounced it correctly, I would still get flack from people. Pronouncing French names is a no win situation. So frankly, I don't care!
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Tool for removing fixed cups in this video:
youtube.com/watch?v=P9oIUmdI5JU
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The tool I used in the video was a Park Tool CCW-2. The Park Tool CCW-15 will work also. And there were similar tools made by other companies as well.
This is where I bought Stanley and other used sockets:
youtube.com/watch?v=ou-CHpKOfYg
IceToolz crank bolt wrench with 14mm and 15mm crank sockets:
amazon.com/exec/obidos/ASIN/B0028NANOU/ref=nosim/youtube25-20
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I have had people ask if the dual pivot brakes are better than the single pivot brakes. Yes they are. They have more mechanical advantage and will deliver stronger, controlled braking. They are also aesthetically more modern looking as well, so that is a bonus.
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How To Clean/Lube A Suspension Seatpost:
youtube.com/watch?v=Q7acUFC2goQ
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FYI, I know the surgical clamp is called a hemostat.
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On this pump head, the lever is pulled up to lock it onto the valve stem. On some other models, the lever is up when put on to the valve stem, and the lever is pushed down to lock it onto the stem.
Replacement Dual Valve Pump Head:
amazon.com/exec/obidos/ASIN/B00426GZJS/ref=nosim/youtube25-20
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Ryobi P737D Cordless Inflator:
amazon.com/exec/obidos/ASIN/B0821S1TZG/ref=nosim/youtube25-20
Ryobi Battery & Charger
amazon.com/exec/obidos/ASIN/B0117TNWTI/ref=nosim/youtube25-20
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