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TW200 Technical help
Started by jefmtbkr at 11-24-2007 7:55 AM. Topic has 46 replies.
  
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 11-24-2007, 7:55 AM
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jefmtbkr
 
Joined on 03-21-2007
Ft Wayne, IN
Posts 290
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Could some of you TW riders show us new guys how you did the Air valve install into your fork caps. Did you buy a kit somewhere or is it a homemade kit? Part numbers would be greatly appreciated. I think making the low air preassure part of the dampening makes alot of sence. I have used Marzocchi forks on my mountain bikes for years and most of them used air pressure for the spring and they ride great.
07 TW200 - Brand New-Ran over-rebuilt-now,Bionic TW
00.5 Aprilia Mille, (Sold)
90 FZR1000 (Sold)
73 Honda CL 350-First bike in 1986(sold)
Motto-Never let the hardships in life interfere with the pleasures of living!!
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11-24-2007, 5:55 PM
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JoMomSophat
Joined on 07-12-2006
Seattle WA
Posts 824
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Re: Air valves on fork caps
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you just drill a hole in your fork caps and tap it and thread a valve
there. you might also want to seal the threads with something,
or have a gasket of some kind.
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11-24-2007, 6:53 PM
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Fourcycle
Joined on 08-01-2007
SE Michigan
Posts 1,229
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Re: Air valves on fork caps
Attachment: cap.jpg
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Schrader valved “test” fittings are available at most good hardware and
plumbing stores. They have a Schrader
valve on one end and a 1/8” NPT thread on the other. This is what I used on my modification. Using a lathe and the letter O (.332” diameter) drill in the
tailstock, I drilled a hole in the center of each fork cap. (After removing them of course.) I then tapped each hole to 1/8” NPT with a
tap, which you can also get from the hardware store. You will need to run the threaded portion of the tap pretty much
all the way into each cap for a good fit since National Pipe Threads are
tapered. Test-fit as you go. I used pipe dope to seal the threads. You will want to use a lathe or vise to hold
the plug while drilling and tapping. Use thick cardboard, etc, to protect the
threads from the lathe or vise jaws.
This can also be done with a drill press or hand drill. The caps have O-ring seals and should not
require additional gasketing to the fork tubes. NOTE: I have
not pressurized mine yet so this is all speculative ;o)
If your only tool is a hammer
everything looks like a nail.
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11-24-2007, 8:01 PM
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elBuro
Joined on 08-17-2007
Mojave Desert SoCal
Posts 113
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Re: Air valves on fork caps
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Exactly what I had done. I run 10lbs each leg and have done several 3 foot jumps with no problems or bottoming out.
2006 Yamaha TW200VC
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11-27-2007, 6:20 AM
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mrgizmow
Joined on 10-21-2006
Paradise, Calif.
Posts 2,439
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Re: Air valves on fork caps
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A tip (i think). If you only remove and modify one cap at a time you should not have to worry about your front end collasping and needing to jack it up to get the springs back down the fork tube so you can thread the caps back on. Take care Gerry
Be safe my Friend.
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11-27-2007, 6:40 PM
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Cyclepath
Joined on 06-28-2007
Posts 836
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Re: Air valves on fork caps
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11-28-2007, 6:13 AM
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Fourcycle
Joined on 08-01-2007
SE Michigan
Posts 1,229
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Re: Air valves on fork caps
Attachment: cap1.jpg
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Cool! I
had never heard of sub tanks or, in some cases, a sub tank. I found this site that
explains what they do and how they work pretty well. Should not be difficult to DIY.
I
think I will stick with just the air caps and go further if I feel like it.
If your only tool is a hammer
everything looks like a nail.
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11-28-2007, 8:16 AM
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Cyclepath
Joined on 06-28-2007
Posts 836
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Re: Air valves on fork caps
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11-29-2007, 4:17 AM
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bronc3
Joined on 10-04-2006
Zero Gulch, Floriduh
Posts 907
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Re: Air valves on fork caps
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Nope, no slammin'.
I agree that 10lbs is pretty high, 3-5lbs seems to be the norm from past experience with air forks.
Bonecrusher Racing
'07 TW200
'03 Busa-sold
'06 DRZ400
'75 DT175
'08 TTR230 (SWMBO)
'05 DRZ125L (shared with SWMBO)
'07 YZ 250
'06 YZ 125 (SWMBO)
'05 Cag
'10 CBR1000 (coming soon)
'08 CRF50 w/6" suspension (the boy's)
'04 CRF50 (the girl's)
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02-07-2008, 6:39 PM
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mrgizmow
Joined on 10-21-2006
Paradise, Calif.
Posts 2,439
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Re: Air valves on fork caps
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Lets once again resurrect the dead........... I purchased some 2" copper pipe, fittings, hose and gauge in an attempt to add an air chamber to get the most out of our marginal front forks. I bought Jeffs V-Star rear shock so I think I will end up with a nicer rear suspension (thanks Jeff) but the front still 'sucks'/ 'boinks'. I will let you all know if my non-scientific air tank assembly nets me anything.. Take care, Gerry
Be safe my Friend.
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02-07-2008, 8:45 PM
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jrcanoe
Joined on 03-24-2007
Pittsburgh
Posts 330
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Re: Air valves on fork caps
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Yes let us know your progress. I have the valves and have been waiting to go to my Dad's for his drill press. I was thinking about a cross over tube so I could pressure both at once but may try to use my handle bars as a sub tank if I can get the ends welded shut.
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02-08-2008, 7:27 AM
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jefmtbkr
Joined on 03-21-2007
Ft Wayne, IN
Posts 290
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Re: Air valves on fork caps
Attachment: images.jpg
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Bicycle shops have little air pumps for the full suspension mountain bikes and high end xc race bikes. You can add 1lb at a time if you want and most are designed to not let any air escape when they are removed.
07 TW200 - Brand New-Ran over-rebuilt-now,Bionic TW
00.5 Aprilia Mille, (Sold)
90 FZR1000 (Sold)
73 Honda CL 350-First bike in 1986(sold)
Motto-Never let the hardships in life interfere with the pleasures of living!!
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02-08-2008, 6:36 PM
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Awfulkanauful
Joined on 01-11-2008
Posts 686
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Re: Air valves on fork caps
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<BLOCKQUOTE><table width="85%"><tr><td class="txt4"><img src="/Themes/default/images/icon-quote.gif"> <strong>jrcanoe wrote:</strong></td></tr><tr><td class="quoteTable"><table width="100%"><tr><td width="100%" valign="top" class="txt4">Yes let us know your progress. I have the valves and have been waiting to go to my Dad's for his drill press. I was thinking about a cross over tube so I could pressure both at once but may try to use my handle bars as a sub tank if I can get the ends welded shut.</td></tr></table></td></tr></table></BLOCKQUOTE>
Hey...If you cant get it done locally , ship them to me...will do whatever you want on them..NC. I really like that idea !
Im out of this Fucking Place !
Chopper Charles has done everyone here a HUGE injustice buy dropping the ball on a properly moderated forum ! He realy doesnt deserve any loyalty from anyone by doing this !
Adios.....!
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02-09-2008, 2:13 PM
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Fourcycle
Joined on 08-01-2007
SE Michigan
Posts 1,229
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Re: Air valves on fork caps
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Just as a heads-up, Bike Nashbar
has a suspension pump
on sale right now.
If your only tool is a hammer
everything looks like a nail.
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02-11-2008, 6:34 AM
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mrgizmow
Joined on 10-21-2006
Paradise, Calif.
Posts 2,439
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Re: Air valves on fork caps
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Well, my computer took a dump yesterday so not sure when I will be able to post pictures again. The tank is in place and working (no real ridding test yet). I have a tube from each fork plumbed into the tank. The extra nipple is for a 0-15lb pressure gauge. The tank seems to fit nicely within the space below the top triple clamp and between the left fork tube and head tube. When the fork is turned to the left extreme, the air tank just clears the gas tank, I hope to post pictures if I can figure out the Wife's software. I think I will need a complete disk restore on mine for the partial restore still does not enable windows to work............ Take care, Gerry
Be safe my Friend.
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02-11-2008, 6:16 PM
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mrgizmow
Joined on 10-21-2006
Paradise, Calif.
Posts 2,439
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Well, will try to post some more pic's. Take care, Gerry
Be safe my Friend.
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02-11-2008, 6:33 PM
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mrgizmow
Joined on 10-21-2006
Paradise, Calif.
Posts 2,439
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Re: Air valves on fork caps
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Well, it looks like I am master of my new universe. Still no real ridding test but for the short trip down the road and into and through the nearest ditch and vacant lot, I would have to say that this project has produced no negatives. Someone requested a shot of the fork cap and fitting, so here is one. Right off the bat I would suggest that you not choose the fitting with the small 3/16" barb, for I have already broke one off. Take care, Gerry
Be safe my Friend.
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02-11-2008, 6:41 PM
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mrgizmow
Joined on 10-21-2006
Paradise, Calif.
Posts 2,439
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Well, it looks like I am master of my new universe. Still no real ridding test but for the short trip down the road and into and through the nearest ditch and vacant lot, I would have to say that this project has produced no negatives. Someone requested a shot of the fork cap and fitting, so here is one. Right off the bat I would suggest that you not choose the fitting with the small 3/16" barb, for I have already broke one off. Take care, Gerry
Be safe my Friend.
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02-12-2008, 11:44 PM
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pjking
Joined on 11-18-2007
Nampa Id
Posts 121
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Re: Air valves on fork caps
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Gerry, that is great, loos great too. I was wondering did you used to race? The reason I ask is because your levers are down quite a bit. That is how I run mine it is commin with racers.
phil
People are like a zit, keep pushing I will blow!
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02-13-2008, 6:23 AM
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mrgizmow
Joined on 10-21-2006
Paradise, Calif.
Posts 2,439
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Re: Air valves on fork caps
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I sure hope it gives the front suspension a better feel, I think I will be able to hit the trail this weekend. My lever position just kind of evolved from the change over of handlebars. The aluminium bars are alot more comfortable cause the flex absorbes alot more road (trail) shock. Is there a more comfortable lever position you would suggest? Take care, Gerry
Be safe my Friend.
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02-14-2008, 6:43 PM
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mrgizmow
Joined on 10-21-2006
Paradise, Calif.
Posts 2,439
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Re: Air valves on fork caps
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Forgive all the caps, but this message merits some real attention....... TRIED MY BIKE OUT TODAY AFTER DOING SOME 'MAJOR' SUSPENSION MODS; I INSTALLED JEFF'S SURPLUS V-STAR REAR SHOCK AND DID A SUB-TANK FOR MY FRONT FORKS. I NOW HAVE A TOTALLY DIFFERENT BIKE........... THE SUSPENSION IS HANDS DOWN, A MILLION TIMES BETTER THAN STOCK........ This of course is all my opinion and may be taken as total bullshit, but none of my mods were my idea so all credit goes to others. Jeff suggested a rear shock mod, and I just moded his surplus shock with nothing more than a extended bracket (20 minutes for grind and weld). I think Jeff as well brought fork (air) sub-tanks to my attention. Over the last two weekends, I modified Jeffs V-Star R. shock and fabricated sub-tank air assist system for the front. My TW is a TOTALLY different ride. The suspension reminds me more of my "super plush" XR 250 Honda than the super crude TW 200. None of what I did was rocket science, or in any way my idea. It was all very simple and put me light years ahead of what I had. Take care, Gerry.
Be safe my Friend.
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02-14-2008, 8:56 PM
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mrgizmow
Joined on 10-21-2006
Paradise, Calif.
Posts 2,439
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Re: Air valves on fork caps
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When the bike was up on my jack, I pumped to 3psi. When I lower the bike, the weight and contact with the ground set the gauge to 4 psi, but I am not sure you can expect the same outcome if you drill your forks and pressure them to 3 or 4 psi. I think the sub-tank adds volume that makes the fork action more supple. I think simply adding air to the fork would just make it stiffer. I am sure that would be ok if you want a "harder" ride. Take care, Gerry.
Be safe my Friend.
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Yamaha TW200 Tr... » TW200 Forums » TW200 Technical... » Air valves on fork caps
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