Front Suspension Problem

Lee1200r · 03-02-2011, 10:10 PM

Just had the front forks taken apart to clean and change oil when we noticed something very strange. The outer fork tubes have two bushings pressed into the inside of the fork tubes. One at the mouth and one about 1/2 way down. One fork tube had only one bushing while the other had two. There was a recessed area for the bushing to go, it was just missing. Since these are pressed in at the factory I am guessing they just missed it. But wanted to check and see if anyone else has had this problem? Tomorrow I will take to dealer and see what BMW says.

Used2be · 03-03-2011, 09:30 AM

Quote:

Originally Posted by Lee1200r

One fork tube had only one bushing while the other had two. There was a recessed area for the bushing to go, it was just missing.

I've had my Sachs forks apart and there was one bushing and one spacer in each fork outer tube. I don't know the factory assembly process for the forks, but could the worker somehow have put two bushings in one tube and none in the other? I don't know if this link will work for you, but Dan Kyle had this posting on his forum about the Sachs forks. If the link won't work, go to Fork Information on his forum.

http://www.***************/showthrea...he-Sachs-forks

Lee1200r · 03-03-2011, 04:18 PM

Quote:

Originally Posted by Used2be

I've had my Sachs forks apart and there was one bushing and one spacer in each fork outer tube. I don't know the factory assembly process for the forks, but could the worker somehow have put two bushings in one tube and none in the other? I don't know if this link will work for you, but Dan Kyle had this posting on his forum about the Sachs forks. If the link won't work, go to Fork Information on his forum.

http://www.***************/showthrea...he-Sachs-forks

Thanks but Dan was talking about the plastic bushings not the metal ones that are pressed in, which are the ones I am posting about.

Used2be · 03-03-2011, 06:05 PM

Quote:

Originally Posted by Lee1200r

Thanks but Dan was talking about the plastic bushings not the metal ones that are pressed in, which are the ones I am posting about.

He did mention in that post on his site that the metal bushings are NOT pressed in and that's why the plastic spacer is there, but you've read it and know as much as I do. Let us know what BMW says about the proper assembly of the forks, thanks. Mine have worked fine since reassembly, so I think everything is OK....?

Lee1200r · 03-07-2011, 02:16 AM

Well BMW is sending me a new outer fork tube with two pressed in metal bushings. So if you have yours apart you might check just to be sure you have both. Again this is not the two plastic bushings that come out when you remove the inter fork tubes.

Used2be · 03-07-2011, 11:28 AM

Quote:

Originally Posted by Lee1200r

Well BMW is sending me a new outer fork tube with two pressed in metal bushings.

That's great that BMW is giving you a new tube, but I wonder how many other bikes have metal bushings that do slide in the tube? Odd that mine and the pair that Dan had did move. Since there isn't a separate part number for the bushings or the plastic spacers, I suppose BMW supplies the tube as an assembled piece. I wonder if the bushings will ever be available separately for rebuild purposes? Are the plastic spacers there just in case the pressed fit doesn't keep the bushing in place? Had the dealership you deal with had any experience with these forks previously? Thanks for the info.

crstuning · 03-07-2011, 11:57 PM

Many companies now machine recesses for fork upper and lower bushings into the fork upper. Simple in the assembly process and much easier when servicing. If you look carefully, both bushings spring into place and can therefore be removed. The lower bushing is easily extracted but the mid/upper bearing requires special tools for that operation.

Both bushings are therefore removable for replacement purposes, but in general with this design they last a lot longer.

Hope this helps!

Dave Moss

Lee1200r · 03-08-2011, 02:21 AM

Quote:

Originally Posted by crstuning

Many companies now machine recesses for fork upper and lower bushings into the fork upper. Simple in the assembly process and much easier when servicing. If you look carefully, both bushings spring into place and can therefore be removed. The lower bushing is easily extracted but the mid/upper bearing requires special tools for that operation.

Both bushings are therefore removable for replacement purposes, but in general with this design they last a lot longer.

Hope this helps!

Dave Moss

Dave if that's the case then why is BMW sending me a new outer fork tube instead of just replacing the bushing that is missing? Seems like an overkill.

Used2be · 03-08-2011, 08:49 AM

Quote:

Originally Posted by Lee1200r

Dave if that's the case then why is BMW sending me a new outer fork tube instead of just replacing the bushing that is missing? Seems like an overkill.

My thinking exactly. Perhaps at the BMW parts level, if they don't have a separate part number for the bushing, they have to send whatever part that includes what you need, therefore the whole tube? Ridiculous of course and I hope they change that. I wonder why Sachs has the recess for the bushing, but felt the plastic spacer was also needed for the upper bushing? Sort of like wearing suspenders and a belt. Maybe some problems with retention and the spacer was the easy fix?