• 2 Stroke Husqvarna Motorcycles Made In Italy - About 1989 to 2014
     WR = 2st Enduro & CR = 2st Cross

  • Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

125-200cc Fork oil change/ lost rebound dampIng

Aviduser

Aviduser

Husqvarna
AA Class
I have a set of 45mm zocchis. I've changed the suspension fluid on my previous husky. Same fork.

But now it seems like I'm not filling the damping rod properly. I fully compress the sliders, fill the damper rod fully and fork chamber most of the way. Then put my finger over the damper rod and cycle it to fill the damper cartridge.

With it full after repeating this I put the inner damper rod back in(fork still compressed). Then finishing topping up the fork. Reassemble.

I've done this twice now and followed the service manual very closely. I can't think of anything I could be doing wrong.

The service manual is for an 04 husky, I have an 08 but the forks appear identical.
 
Did you have a loss of rebound before the change which maybe prompted this service? Either way, a loss of rebound could be explained by a problem with the mid-valve stack, or the checkplate if there is no midvalve. To check it you need to remove the cartridge, spin the nut off the top, wrap the threads in teflon tape, and push it from the cartidge. The rebound stack ( against the nut) could have debris trapped in it, or the float in the midvalve could have bound and prevent it from clamping to the piston, or perhaps the spring/checkplate has an issue. ive seen a checkplate start threading itself down a spring effectively eliminating any rebound control.
 
Ok guess I'll have to dig a bit deeper into the fork.

Really confusing, no issues before oil change. Only removed springs, preload spacers and top caps.

And both fork legs have the same issue. I tried a 3rd time re doing a fork leg. No dice. Frustrating
 
I'm using 5 wt oil. But really doubt that would be the problem. As is the fork tops out like a pogo stick.
 
OK then maybe cartridge isn't filling. Add oil. Ignore cartridge, raise outer tube, clamp hand over it and compress, using trapped air to force oil into cartridge. you should be able to work the cartridge rod and feel the air bleeding. Don't clamp finder over the rod, let oil flow.
 
Gave it a shot but no luck with that method either.

Thanks I really appreciate your help though.

Think ill check out the lower internals tommorow.
 
Well pulled both fork legs apart. checked shim stack, check plates clear of debris moving freely.

Refilled everything again. Still absolutely no rebound dampening. At my wits end.

I just can't fathom what's wrong. Maybe I shouldve tried running 10w to see if that makes a difference.

Might have to take it in to a suspension shop. Sheesh what a can of worms for a routine fluid change
 
Having both forks go at the same time sounds a little weird also ...

Is the 5WT oil the same as you have used before in your forks?

--

I did read an article once where some valving on a specific fork needed 7.5 WT and above oil or it would not work properly because some of the holes in the valves needed that oil weight or it just passed through some of the valves and provided no dampening ...

Might be worth a shot to try one leg with heavier oil before you reach for your wallet ...
 
Same thing happened to me, no oil in the cartridge. 5wt oil is fine you just need a way to get oil into the cartridges; I used a syringe it takes awhile with this method.
 
Finally!!

After trying to re fill/ bleed the damper rod from the top for 30min.

I removed the whole cartridge again. Inverted it with the rebound rod in. Filled while cycling the rod. Reassemble. Super easy and fast. I found the idea through this link.

http://www.dirtrider.net/forums3/text/topic/133279-1.html

I strongly suggest anyone use this method. Coulda saved me hrs of frustration.

Thanks for all the help guys. Stoked I can actually ride today
 
Very odd! I've never had that happen and have done scads of them, as well as mid-90's KYB's practically the same. The old hand over the female leg and compress works every time. Anyway glad you got it handled!:thumbsup:
 
You must log in or register to reply here.
Back
Top