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

Dirt bike forks are subject to a lot of wear and tear, and they need to be regularly serviced to keep them in good condition. Fortunately, the tools you need to rebuild them are relatively simple and can be easily sourced from your local hardware store.

The first thing you’ll need is a set of fork seals. This seal the airtight area between the stanchions and the tubes, and they should be replaced if they’re damaged or excessively worn. You’ll also need some new fork oil to lubricate the seals and moving parts. When choosing fork oil, it’s important to select the right viscosity for your bike – if it’s too thick, it will make the forks feel stiff, and if it’s too thin, it will cause excessive ‘stiction’.

You’ll also need a set of locknut sockets to remove the retaining bolts at the bottom of the forks. Once these are removed, you can then begin disassembly. Be careful not to lose any small parts during this process, and make sure that you clean all of the componentry thoroughly before reassembling. With patience and attention to detail, rebuilding your dirt bike forks is a relatively straightforward task that anyone can do at home.

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

Begin by removing the front wheel and fender from your bike. You’ll also need to disconnect the brake line and speedometer cable (if applicable).

Removing the Front Wheel


Next, remove the bolts that hold the fork legs in place. These bolts are usually located at the top and bottom of the fork leg.

Remove Bolts of Bike Forks

Step 3

Once the bolts are removed, gently pull the fork leg out of the bike frame. Be careful not to damage any other parts in the process.

Step 4

With the fork leg removed, you’ll be able to access the internals of the fork. Remove any dust seals or retaining rings that may be present.

Step 5

The next step is to disassemble the damper rod assembly. This can be done by unscrewing the damper rod cap and sliding out the piston rod.

Step 6

With the damper rod assembly removed, you can now begin cleaning all of the components. Start with a degreaser and then move on to a cleaner designed specifically for suspension components.

Step 7

Once everything is clean, you can begin reassembling the fork components in reverse order. Be sure to lubricate all of the moving parts as you go.

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.

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?

In order to have your forks rebuilt, it will cost you anywhere between $70 and $200. The cost will largely depend on the quality of the fork and whether you have it done by a professional or not. If you decide to do it yourself, you can find fork-rebuilding kits online or at your local bike shop.

These kits typically include new seals, bushings, and air-sprung internals. On the other hand, if you want to leave it to the professionals, they will typically charge by the hour. In either case, rebuilt forks will generally last for several seasons before needing to be serviced again.

How Often Should You Rebuild Motorcycle Forks?

Motorcycle forks are vital components of the suspension system. They utilize stanchions that move up and down in corresponding tubes filled with hydraulic fluid. The result is a damping action that soaks up road irregularities, providing a relatively smooth ride. Over time, however, the stanchions can become scratched, and the seals can fail, allowing oil to leak out.

When this happens, it’s time to rebuild the forks. The frequency with which you will need to do this will depend on how often you ride and the conditions of the roads you typically ride on. However, as a general rule of thumb, you should plan on rebuilding your forks every 20,000 to 30,000 miles. Doing so will help to ensure that your motorcycle continues to provide a smooth ride, no matter where the road takes you.

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 dirt bike forks can be a daunting task, but if you follow these instructions carefully, you should have no problem getting the job done right. And once your forks are rebuilt, they should last for many rides to come. We have described how to rebuild dirt bike forks in this article. Thanks for reading.

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