RSV Factory Fork Clamp Cracking

Hi Guys,

I got some time today, to spend on my bike. Which was spent cleaning the grime off it from a couple of months of sitting in the garage & the odd commute to work. While i was cleaning the front, i noticed that the forks are showing signs of cracking :argh



Now it hasn't currently cracked all the way to the edge & I have been desperately trying to convince myself that this is not an issue but clearly it is. I've heard that this isn't uncommon & caused by overtightening the bolts.

Does anyone know where i can get a replacement bottom & how easy it is to change it? Obviously, with the first signs of spring, this has taken on a new level of urgency as i don't really want the bike off the road for the next 3 months.

I maybe interested in a replacement set of forks, if anyone has a spare set floating around, i can then get this fixed at my leisure.

Cheers

Lee.

Nasty m8 those allen head bolts have been well over torqued if so ......it may be ok for a while, but it is certain to BE DISASTROUS........get it fixed or it will be you being fixed.......
mind you I can't quite tell if it is a crack from the pic as its not in enough detail are you sure its not a casting mark?????

Yeap, It's definately cracked. I know it's not obvious in the photo & i was also hoping that it's a casting mark so removed the spindle earlier and it is through to the inside.

I'll have to order up a replacement, assuming i can & get it rebuilt.

Sorry to hear that bud who did the bolts up last I would be on to em like a shot..........if it was a reputable dealer then that is real bad, when you undid the allen bolts did they feel overly tight??

Yup afraid it's cracked due to over tightening of the pinch bolts, apparently this is quite common & costs about £300.00 to replace the bottom of the fork legs. My local Aprilia dealer warned me to look out for this when I was looking to replace mille.

Hope some1 warns U about Pinky & Perky in the dark...u might not see em and stub ur eye son HE....HE

I guessed as much, I read about the issue online somewhere, which prompted me to check. Unfortuately I bought the bike a year ago on a whim & it would appear should have paid more attention.

Can you order the parts through an aprilia dealers or do I need to go to a suspension specialist?

Can't help you there bud, mine are Showas so best left to some1 who does, I am sure that a descent Ohlins dealer will be able to sort it for a reasonable cost if not just look for a second hand fork leg sold singularly and u should get a bargain ...if I remember rightly someone on here has got some damaged ohlins legs and is lookin to sell em, ask around dude

Just had a brainwave :dowhat I'm sure it was RSVSTEVE search him out dude......

I noticed the same thing after buying my bike. As said previously, its due to overtightening the bolts.
I cant remember axactly but the torque setting is very low 12Nm rings a bell but not 100% sure.
Im afraid you will need the fork bottom replacing. You could try a repair from a specialised aluminium welder if you can find one.
I got the fork bottom replaced then bought a torque wrench specifically for low settings.
Hope you get it sorted soon.

You need special clamps apparently to hold the stantions, as they unscrew. Replacements are alot cheaper than buying second hand ohlins

2TROKE said:

Hope some1 warns U about Pinky & Perky in the dark...u might not see em and stub ur eye son HE....HE

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I'm willing to take the risk :devious:biggrin

nikfubar said:

I'm willing to take the risk :devious:biggrin

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With ur permission so am I ..........Can I please Begsy 1st.....:hail

Replaced my left lower this is the one which breaks the most .... Don't try to weld this !!!!!!!! I have being welding & teaching welding for 36ys & wouldn't even look at welding this not that I couldn't , there are somethings which you just don't **** with ! this is one of them , brakes is the other no brainer ... Get your ohlins dealer to sort it out & ride safely with piece of Mind ..

Cheers guys, don't think I'd ever be happy with a welded lower, even if it was successful I'd always doubt it. Replacement it is. I'll constant a couple of ohlins dealers today and see what the costs and delay is. It's a shame I noticed it now as I could have sorted it over the last couple of months when it hasn't had much use.

Shame really as I was gearing up to spend the funds on some toys for it.

I spoke to Steve Jordans today & they are able to order the bits, they requested that i get the code from the inside of the fork leg, which meant that i had to drop the wheel to be sure. Pinch bolts are not much passed finger tight, so i guess at least on this occassion they were torqued to the correct level, however in the past it would seem that wasn't the case.

My initial thoughts were to replace both legs as i am assuming they've both been over torqued but the RHS (if you're sitting on the bike) shows no damage or markings inside & out, so i think i'll leave it. I may regret this one day but for now i'll take the risk.

I also got an email response from K-Tech, quoting err, £1665.00 + VAT for each bottom, i am sincerly hoping this is a typo as everything i've read so far would point to them being approx £150.00 each. They did, however offer a service to revalve the forks while they were apart and fit one of their piston kits, which i'll probably have fitted while they're being serviced.

Ohh and i might as well get the shock serviced while the front is getting attention. I get a feeling my finances are going to take a pounding due to this...

While this is all apart, i was thinking about getting the wheels powder coating, as they're showing signs of the finish wearing thin, can the OZ wheels be stripped & coated easily?

Ho hum, the project has now officially started, looks like my old Kawasaki is going to be called into service in the next couple of months while this thing is apart.

yep thats a typo if it's just a quote for the knuckle - they're around £160 + vat. the wheels are a cinch to do matey - I have had mine done no worries :thumleft:

Deacs said:

yep thats a typo if it's just a quote for the knuckle - they're around £160 + vat. the wheels are a cinch to do matey - I have had mine done no worries :thumleft:

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that does sound a little better value :laugh

dont spose they get many jobs if they keep quoting that price either :roll

If your going to get the wheels powder coated I would reccommend these people

http://www.aerocoat.net/EnterTitleWHEELPOWDERCOATING.htm

They did the wheels on my hybrid for £100.00 cash each wheel

wow thats a lot of money nick!! although they do look the nuts :thumbup I think its probably because you look like you've gone for a chrome and candy colour?!

I paid £100 for both of mine in gold

I like the gold wheels, i've been wondering what colour to get them done. Mine are currently blue & the bike is red and silver. I doubt I'd find a blue close to the original colour so I'm thinking of other options. My favoured choice at the moment is white but I'm open to suggestions.

As for the suspension, lower is now on order & should arrive in 3 weeks. K-tech piston kit is also on order and will be fitted at the same time & shock ibogging to be serviced. hopefully when all this is done, I should see some benefit from the expense.

Next step, fuelling!!! Fitted a full akrapovic system back in October and haven't done anything about mapp
Do I put a carbon airbox on it before fitting a power commander or bazzaz?