How to Rebuild Dirt Bike Forks

How to Rebuild Dirt Bike Forks


Dirt bike forks take a lot of abuse, so it’s not uncommon for them to need rebuilding from time to time. In this article, we’ll show you how to rebuild dirt bike forks using some simple tools and supplies. We’ll also provide some tips on keeping them in good condition for longer. If you’re looking to get the most out of your dirt bike, then read on!

How to Rebuild Dirt Bike Forks

Tools We Need to Rebuild Dirt Bike Forks

Let’s have a look what are the tools actually we need to rebuild dirt bike Forks:-

Let’s have a look what are the tools actually we need to rebuild dirt bike Forks:-

  • Socket set or wrench set: You will need a variety of sizes to remove bolts and nuts.
  • Screwdrivers: You will need both flathead and Phillips head screwdrivers for various tasks.
  • Hammer:  A small, lightweight hammer will be useful for tapping on certain components.
  • Seal driver:  This is a specialized tool that helps you install new seals in the forks.
  • Oil pan:  You will need a container to hold the oil that drains out of the forks.
  • Clean rags:  You will need a few clean rags to wipe away excess oil and dirt.
  • Shop manual:  It is helpful to have a shop manual for your specific dirt bike model to refer to during the rebuilding process.
  • Optional:  If you have access to a hydraulic press, it can be helpful for certain tasks during the rebuild.

How to Rebuild Dirt Bike Forks

When it comes to dirt bike forks, there are two main types: air forks and spring forks. Air forks are the most popular type of fork, as they offer a smoother ride and are easier to adjust. Spring forks, on the other hand, are best for riders who frequently ride in rough terrain. No matter what type of fork you have, though, eventually it will need to be rebuilt. Luckily, it’s not a difficult process, and can be done in just 10 steps.

Step 1

The first step in rebuilding your dirt bike forks is to remove the front wheel and fender. This will give you access to the fork legs and the inner workings of the forks. To remove the front wheel, you will need to loosen the axle pinch bolts that hold the wheel in place. Once the bolts are loose, you can slide the wheel out of the fork legs. Be sure to support the bike while you remove the wheel to prevent it from falling over.

Removing the Front Wheel


In this stage, we remove the bolts that hold the fork legs in place. These bolts are usually located at the top and bottom of the fork leg. The brake line is typically connected to the caliper, which sits at the back of the fork legs. It is held in place with a banjo bolt, which you will need to remove with a wrench.

Remove Bolts of Bike Forks

Step 3

After finishing the step 2 we just reached in step 3. In this stage when we removed the bolts then we gently pull the fork leg out of the bike frame. Be careful not to damage any other parts in the process. The fork legs are connected to other parts of the bike such as the brake caliper, speedometer cable, and axle, so it’s important to be gentle when removing them.

Step 4

Now in this stage we already see that fork leg removed and you will have access to the internals of the fork. The first step is to remove the dust seals and retaining rings that may be present. Dust seals are located at the top of the fork leg and keep dirt and debris out, while retaining rings are located at the bottom of the fork leg and hold the fork spring and the damping rod in place. Removing these parts will give you access to inspect the fork spring and the damping rod for any wear or damage.

Step 5

In Step 5 disassemble the damper rod assembly. This can be done by unscrewing the damper rod cap and sliding out the piston rod. Disassembling the damper rod assembly will allow you to inspect the internal parts for any wear or damage and to replace them if necessary.

 The damper rod cap is located at the top of the fork leg and is typically held in place with a few threads. Use a suitable tool such as a spanner wrench or an adjustable wrench to remove the cap.

Once the damper rod cap is removed, you will be able to access the piston rod. The piston rod is a long metal rod that runs through the center of the fork leg. It is connected to the damper rod cap and is responsible for controlling the rebound of the fork. To remove the piston rod, gently slide it out of the fork leg. Make sure not to damage the rod or any other internal parts.

Step 6

With the damper rod assembly removed, you can now begin cleaning all of the components. It is important to thoroughly clean all of the parts to ensure that they are free of dirt, debris, and any old lubricant. This will allow you to properly inspect the parts for any wear or damage and to ensure that they are in good working condition.

Start by using a degreaser to remove any dirt and grime that may have accumulated on the parts. A degreaser is a cleaning solution that is specifically designed to remove grease and oil. You can apply it to the parts using a brush or a rag, and then rinse it off with water.

Once you have removed the majority of the dirt and grime, move on to a cleaner designed specifically for suspension components. These cleaners are specially formulated to remove any remaining dirt and grime, and to leave the parts clean and dry. You can apply the cleaner using a brush or a rag, and then rinse it off with water.

Step 7

Once everything is clean and dry, you can begin reassembling the fork components in reverse order of disassembling. This means starting with reassembling the damper rod assembly, then the dust seals, retaining rings, and then reinstalling the fork legs back to the bike frame.

As you go through the process, be sure to lubricate all of the moving parts with the recommended lubricant. This will ensure that the parts move smoothly and will help to prevent wear and damage. Remember to torque the bolts and nuts to the manufacturer’s recommended torque to ensure proper alignment and prevent any issues in the future. I won’t take too much of your time, we only have two steps left in the process.

Step 8

When everything is back in place, bolt the wheel firmly in place and reconnect the brake line and speedometer cable (if applicable). You may need to bleed your brakes after this step. Refer to your bike’s manual for instructions on how to do this correctly.

Step 9

The final step is to test your work. Take your dirt bike out for a spin and see how the new forks feel. If everything feels good, then you’re all set! Otherwise, you may need to readjust the air pressure or spring preload before heading out again.

And there you have it! You’ve successfully rebuilt your dirt bike forks and they’re ready for another season of riding. Enjoy! Thanks for reading! By reading all these steps you have got knowledge of how to rebuild dirt bike forks.

Rebuilld Dart Bike Forks

And there you have it! You’ve successfully rebuilt your dirt bike forks and they’re ready for another season of riding. Enjoy! Thanks for reading! By reading all these steps you have got knowledge of how to rebuild dirt bike forks.

How Much Does It Cost to Have Your Forks Rebuild?

The cost of having your forks rebuilt can range from $70 to $200, depending on the quality of the forks and whether you have the work done by a professional or attempt to do it yourself. If you choose to rebuild the forks yourself, you can purchase fork-rebuilding kits online or at a bike shop.

When the stanchions become scratched or the seals fail, it is necessary to rebuild the forks. The frequency of this maintenance depends on your riding habits and the conditions of the roads you typically ride on, but as a general rule, it is recommended to rebuild the forks every 20,000 to 30,000 miles. This will help maintain a smooth ride for your motorcycle.

How Often Should You Rebuild Motorcycle Forks?

It typically takes anywhere from a few hours to a full day to rebuild a fork, depending on the specific fork and the experience level of the person doing the rebuild. Some forks can be more complex to rebuild than others, and some people may be more skilled at rebuilding forks than others.

Here are some general steps involved in rebuilding a fork:

  • Remove the old fork from the bike. This involves loosening the bolts that hold the fork in place, and then carefully removing the fork.
  • Strip the fork down. This involves removing all of the old parts, including the seals, bushings, and any other components.
  • Inspect the fork for damage. Look for cracks, dents, or any other signs of damage. If the fork is damaged, it may need to be replaced rather than rebuilt.
  • Clean the fork. Use a degreaser and a scrub brush to clean off any dirt or grime that has accumulated on the fork.
  • Install new seals and bushings. These parts wear out over time and need to be replaced in order to keep the fork functioning properly.
  • Reassemble the fork. Put all of the parts back together, making sure to tighten all bolts to the proper torque.
  • Install the fork on the bike. This involves attaching the fork to the bike frame and adjusting it to the proper position.

Overall, the process of rebuilding a fork can be quite involved, and it requires a good understanding of bike mechanics and attention to detail. It can also be physically demanding, as it often involves working in tight spaces and handling heavy parts. However, with the right tools and experience, it is something that most people can do on their own.

How Long Does It Take to Rebuild a Fork?

A fork can last a long time with the right maintenance, but eventually, every fork will need to be rebuilt. The good news is that it’s not as difficult or time-consuming as you might think. With a few simple tools and a bit of patience, you can easily rebuild your fork in about an hour.

To start, you’ll need to remove the old fork from your bike. This will involve removing the front wheel and brake caliper, as well as the stem and handlebars. Once everything is removed, you can begin work on the fork itself. First, remove the old dust seals and wipers. Next, unscrew the top cap and remove the spring assembly. Then, take out the damper cartridge and air spring. At this point, you should be able to remove the stanchions from the lowers.

Now it’s time to clean everything thoroughly and inspect for wear. If everything looks good, you can start reassembling your fork. Start by installing the new dust seals and wipers. Then screw in the top cap and add the spring assembly. Next, install the damper cartridge and air spring. Finally, put everything back together in reverse order – first the stanchions, then the lowers, then the rest of the components. With that, your fork will be good as new!


Rebuilding the forks on a dirt bike can seem challenging, but with careful attention to detail and by following the steps outlined in this article, you should be able to successfully complete the job. After the rebuild, your forks should be good as new and ready to withstand many future rides.

Keep in mind that rebuilding dirt bike forks requires a certain level of mechanical knowledge and can be physically demanding, so be prepared for a bit of a challenge. However, with the right tools and some persistence, you can get the job done.

134 thoughts on “How to Rebuild Dirt Bike Forks”

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