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[kiwi]

Started to fix up the SERK today. Changing the suspension to Traxxion and Bitubos. Had to improvise a bit as there are no instructions available for Harleys yet. Also a tool to compress the spring would have saved us a bit of trouble as we had to muscle the thing up in the end with the help of a clever bit of improvisation.
Check out the pics. This first pic is HDs crap that we pulled out of the tubes.

[kiwi]

We had to grind the base of the fork tube just a whisker so we could knock the HD crap out so the AK-20 cartridge could seat in the bottom. Once you have it ground down you use a socket of the correct dia inside the tube and it knocks the crap out the bottom. Tidy it up so its smooth as babys bum and its good to go.

[kiwi]

We have the AK-20 cartridge installed and have put in some fork oil. Here my mate Phil is pumping the fork to get rid of trapped air. You also need to pump the cartridge rod to get rid of air. We did this until the fork moved smoothly and without any hits and misses.

[kiwi]

Spring sitting in place.

[kiwi]

This is a shot of some essential components. The little brown bottle with the green label is holding a fortifying liquid known to aid mechanics who are working without the correct instructions and or tools.

[kiwi]

This is quite tricky and required some fortifying liquid to get the right solution. We needed to hold the cartridge rod up while lowering the spring over it but without releasing the rod. Answer was to hold it up with the screwdriver and simply rotate the spring and it wound itself down.

[kiwi]

We needed a way to hold the rod up while we positioned the spacer that needed to go on. A piece of rubber tubing was pushed onto the threaded end of the rod. This was a good start but more brain stimulation was required and so the fortifying liquid was employed again.

[kiwi]

Now for the hard bit. How to compress that dirty big spring with the spacer on it while not dropping the cartridge rod, and oh yeah then screw on the top cap.
No photo of how we did it because it took both of us to get it done. I held the hose while phil pulled the spacer down to clear the top of the cartridge rod. I then whipped the hose off and screwed the cap on a few turns before he had to let the thing go. A few more goes at that and it was on.

[kiwi]

We reused the o-ring from the Harley Caps. Looks like it might be right I reckon.

[kiwi]

Slide the fork up over the seal and screw it up into place.

[kiwi]

Just a gentle nip up with the wrench and its ready to go back on the bike.  Unfortunately not all the parts arrived in the kit so I have to wait until the missing parts arrive before I can finish reinstalling them. Dan from Traxxion has them on there way. More pics etc to come as I continue my journey to make my ride safe and useable.
When I went to install the Bitubos on the rear I could not get clearance between the muffler on the right side of the bike and the Axle Nut. The Bitubos are 1" longer than the stock shocks. Any one else had this problem? I have not tried the fortifying liquid on this problem to date but it could be the answer.

[HogBreath]

Does the traxion kit come with a six pack or did you have to supply your own?

[Hoist!]

Great shots of the process kiwi!!! Thanks for posting them! Guess you got the Nacelle off!

Nice to see someone doing it themselves instead of sending the legs down to Traxxion. Much more than I'd ever get into! Innovative specialty tools too! Especially the Fortifying Liquid!!!

I hope ya like em! And you can turn the rear axle around if that helps!

Hoist!

[miker]

Awesome Kiwi...Ah the power of liquid fortification, amazing stuff.   

[mr_magoo]

  my kind of mechanic.

[kiwi]

Does the traxion kit come with a six pack or did you have to supply your own?

No I'm afraid that was not supplied as part of the kit BUT perhaps the guys at Traxxion could look into the benefits of doing so
Cheers, Kiwi

[kiwi]

Great shots of the process kiwi!!! Thanks for posting them! Guess you got the Nacelle off!

Nice to see someone doing it themselves instead of sending the legs down to Traxxion. Much more than I'd ever get into! Innovative specialty tools too! Especially the Fortifying Liquid!!!

I hope ya like em! And you can turn the rear axle around if that helps!

Hoist!

Thanks Hoist. Yes getting the Nacelle off was straight forward, it is the cover over the steering lock that is a concern. Another member has advised that international models ship with tamper proof screws and I will need to employ an easy out to remove them.(see pic) He also suggested replacing them with USA screws. I will need to do this if a handlebar change is required in future. Thanks for the kind words, I do have a lot of faith in the fortifying liquid. The right kind of music playing also creates the right atmosphere for this type of work and combined with a bit of the liquid and a riding mate, very enjoyable chore.
As far as the rear suspension goes I think I will wait until the 2-1 pipe arrives and then reverse the axle and fit the pipe. Should be good to go I reckon
Kiwi

[Twolanerider]

Watched them do this at Traxxion Dynamics and watched your thread here Kiwi.  It's not that the boys in Georgia don't run a friendly shop.  They sure do.  But I think you still had more fun.  Hell, they don't even get LF during the job.  So yours had to be better .

[kiwi]

Watched them do this at Traxxion Dynamics and watched your thread here Kiwi.  It's not that the boys in Georgia don't run a friendly shop.  They sure do.  But I think you still had more fun.  Hell, they don't even get LF during the job.  So yours had to be better .

Thanks Twolane, I find it's the little things in life that make the difference and getting the atmosphere right on a job like this just seems to make all the difference to the enjoyment factor. Now I know what is inside those forks and how it functions I am much happier.
Cheers, Kiwi

[resqdoc]

With the "New Zealand" title, I figured you were going to install them upside down 

[Talon]

Great thread. Overall how was the job? Did you get a chance to take a good ride yet? 

[kiwi]

Great thread. Overall how was the job? Did you get a chance to take a good ride yet? 

Hi Talon. Yes I went out for a ride on the one fine day we had this last weekend. Just awesome, the cornering was so sweet that her on the back commented we seemed to be going much faster in the corners than we were on the original suspension . Had a lot of gusting wind over the top of the range I was riding over and the bike is better behaved in these conditions also. The whole thing is just a lot more solid and I feel relaxed and confident because it is consistant and predictable whereas I did not feel like that before I changed out the suspension up front. :2vrolijk_21:It's all good.
Kiwi

[kiwi]

With the "New Zealand" title, I figured you were going to install them upside down 

Why, because I live on the bottom of the world
Kiwi

[REGGAB]

Why, because I live on the bottom of the world
Kiwi

  Now that's some funny chit right there!  Good one, kiwi!