Front Suspension Fork Modification for Ruck/Met et

[AweShucks]

Hey gang thought I would spread the info as posted at the Urbanscootin.com forum. I just finished about 3 weeks worth of trial and error testing on an idea I had to improve the front suspension. It worked out very well and I put together a guide for all to view.

So the stock forks on your Met or Ruckus just don't cut it hey? Bottom out often and hard? Do you think the front end is going to fall off next time you hit a bump? Do you find yourself avoiding bumps?
Well here is your home grown fix put all together for all those who need something better and seek a more enjoyable ride.
After many hours of trying out several different changes and alterations I have come to this final modification. Overall the results were better than anticipated. I was very pleased with the outcome. So pleased actually that my aftermarket Showa shock feels inferior now!
Much better performace and feel will result from this mod. So if your not happy with the stock ride and feel of the front suspension here is your $25 or less fix. The attached PDF file will provide all the information you need to purchase and perform this procedure.


Have fun, scoot safe, and enjoy!

Comments welcome............


AweShucks



Download PDF 1.2 MB Please DISABLE all download managers prior to download!
For best results save file to disk

rapidshare.com/files/377315982/Front_Fork_Mod_rev._8.pdf.html

[jrcanoe]

I run 2extra rebound springs in the same place as yours and a half spacers.. Plus an extra rubber stopper So untill our suspentions bottom out they are the same. I like your idea of useing an xtra inside coil spring to control bottom out. and will try it . My front is so stiff now it rarely bottoms out anyway.but I have noticed with mine if you do bottom out it feels like it wants to pogo the front off the ground when it returns.

[Dandy Dan]

Aweshucks, my spring didn't arrive last week so I wasn't able to do this mod on the weekend. Hopefully they arrive this week. Thanx for the pioneering ;D

[BMR]

I am having problems viewing the downloded pdf...
Anyone else experience that?

[AweShucks]

Try saving the file to disk. I'm hosting it from my PC until I find a more permanent host.

Edit: I have changed to my ISP host downloads should be more reliable now?

[chanito]

great post, thanks for sharing, maybe we should have some one post a how-to
Two thumbs up ;D ;D

[AweShucks]

jrcanoe said:

I run 2extra rebound springs in the same place as yours and a half spacers.. Plus an extra rubber stopper So untill our suspentions bottom out they are the same. I like your idea of useing an xtra inside coil spring to control bottom out. and will try it . My front is so stiff now it rarely bottoms out anyway.but I have noticed with mine if you do bottom out it feels like it wants to pogo the front off the ground when it returns.

I agree adding the two rebound springs make a ton of difference. The stock configuration was just too weak! I looked for a replacement main spring but they were a little expensive to buy for trial and error purposes. If a person knew which one exactly to try you can buy a set for about $15 - 20 from several different suppliers but they wouldn't be progressive like the stock one.
I was initially worried about the "pogo" effect when I started this Mod. However I don't really notice it with the die springs. I think however regardless of what we use whether it be die springs or extra rubber cushions we will always have the "pogo" effect. Mainly because we have no oil dampening to slow the return.
The die springs are more than adequate to soften the bottom outs and if you don't ride on bumpy streets or offroad just one spring will be enough. I tried stiffer springs and they were too hard. These medium duty springs seemed the best overall.
I even added a spring to my Showa shock being a large guy at 240lbs even the Showa was too weak. All I did was remove the eyelet and add fender washer and cushion to protect the shock and eyelet from the die spring. Worked like a charm

[Dandy Dan]

Your package with the springs arrived at my parents place yesterday. I've already purchased some good snap ring pliers so I should be ready to rock come Saturday.

[jrcanoe]

aweshucks said:

I even added a spring to my Showa shock being a large guy at 240lbs even the Showa was too weak. All I did was remove the eyelet and add fender washer and cushion to protect the shock and eyelet from the die spring. Worked like a charm

I thought about this when I was using the stock rear shock, but could never find a spring to fit inside or out side of the stock spring. I am 1 down from highest pre load setting on my chrome shock. for just me. I would like to try a die spring to get it perfect at 0 pre load. That way I would have full adjustment for extra gear or rider.

[jrcanoe]

aweshucks said:

I agree adding the two rebound springs make a ton of difference. The stock configuration was just too weak! I looked for a replacement main spring but they were a little expensive to buy for trial and error purposes. If a person knew which one exactly to try you can buy a set for about $15 - 20 from several different suppliers but they wouldn't be progressive like the stock one.
I was initially worried about the "pogo" effect when I started this Mod. However I don't really notice it with the die springs. I think however regardless of what we use whether it be die springs or extra rubber cushions we will always have the "pogo" effect. Mainly because we have no oil dampening to slow the return.
The die springs are more than adequate to soften the bottom outs and if you don't ride on bumpy streets or offroad just one spring will be enough. I tried stiffer springs and they were too hard. These medium duty springs seemed the best overall.

I first did this

"At 150# I just about bottom out the front fork. Heavier people must have no suspension at all.

I stopped by the hardware store and bought a pair of 1-1/2 x 3-1/4 springs, Made by Century Spring Corp. model # C-806.
I put the springs over the top part of the fork and installed the forks back up into the pinch bolts. It took alot of arm strength to compress the new spring to get the fork grove and the top bolt to line up but I did it by hand.
The new springs are almost completely hidden by the front fender.
Test drive was wonderfull. HUGE improvement. Best 8$ I'v spent. "

That worked well but it began to tear up the seals.

I am willing to live with the pogo effect and will try you die springs to see if they help.

I want to ride someone's ruck with the dio fork kit before I shell out that kind of cash. I can't see how it could be that much better than my modded stock suspension but it might be worth it for the hydraulic disk brakes

[AweShucks]

jrcanoe said:

I thought about this when I was using the stock rear shock, but could never find a spring to fit inside or out side of the stock spring. I am 1 down from highest pre load setting on my chrome shock. for just me. I would like to try a die spring to get it perfect at 0 pre load. That way I would have full adjustment for extra gear or rider.

I used the same type of spring on my Showa 2.5" x 1" Medium duty and I now have full adjustment available. Basically the best method is to go by the Shock shaft diameter and order the spring based on the right I.D. to fit it going just slightly larger.
The ride is a little stiff and it took away from my overall travel but it bottoms out so much smoother. Doing this would allow someone all the way up to 325lbs maybe more to ride the Met or Ruck IMO. I would also suggest this for someone who does some offroad with the ruck or carries a passenger like you mention.
It's easy enough to do and cheap enough to try it took me about a half hour to do for about $5. Just be sure to add some washers to protect your shock. I used the thin fender style with nylon spacer from ace hardware.

[ward]

i was just wondering if any one can get the link in the first post to work or if you could post a new link
thanks

[Kami no Chiizu]

Try this one, instead...

webpages.charter.net/aweshucks/Front%20Fork%20Mod%20rev.%208.pdf

Should be the same thing... for some reason, the underscores have turned into their numerical equivelent... ( "_" is now "%20" )

[chanito]

Great work moderator ;D ;D

[bigskybassguy]

Thank YOU, Aweshucks. I just did that mod this morning on my `07. It took about an hour, and in the short amount of testdriving, hitting potholes and such is definitely easier on my old geezer bones.

The only correction to all this I'd say is that the parts with shipping are now about $32 (as of Ap `07). You rock.

[eq]

I've been reading the few front shock mods posted, and I'm still a little confused. Before I take apart my forks maybe someone might check me on a couple things??

First, it looks like both sides of the fork are the same - except the right side has a rubber stopper? Do both sides already come with rebound springs, or does one side not have one (the right?) - and one mod is to add a rebound spring?

Another mod is to replace the rubber stopper on the right fork with a "die spring" and a new piece made out of the rubber stopper - and to do the same thing to the other fork leg (cutting down the "guide bushings" - the white plastic pieces, in half or so)?

All the procedures in the aweshucks mod are for someone weighing 240lbs or so: which procedure would be appropriate for someone weighing only 175lbs or so? The pdf says 'add only 1 die spring if you weigh less than 200lbs': does this mean do everything else as well - but when it comes to the die spring procedure add only one of the die springs? I guess without having taken apart my forks I don't understand what else there is to do - if there are already 2 rebound springs. If there is only 1 rebound srping I'm not sure why one would have to purchase 2 for the mod (like it says at the top of the pdf)...

I guess that's it. Insights much appreciated...

Overall, I'm looking to eliminate/drasticaly reduce the nasty bottoming out on my Met and to stiffen the ride. The front shocks are too spongy, soft, weak: I want them firm, tight, an increased range of usefullness (i.e. stop that thwack!)...


OK, let me try to answer some of my questions after having inspected the diagrams again...

The main mod is to replace the rubber stopper with a die spring and a modified rubber stopper. The order of installation of parts/function, not really clear from the diagrams in manual or pdf picts, is this:

-bottom case, die spring, modded rubber stopper, main spring
-bottom end of fork tube (plastic stopper of some sort) depresses against mainspring, deflects against mainspring on compression
-under severe compression bottom of fork tube will deflect against new die spring/rubber stopper
-lower half and upper half separated by some space and a metal race, upon which the upper rebound parts are mounted
-on 'rebound', the rebound spring and modded guide bushings deflect against the top of the fork/bottom case, or whatever - they hold the top and act like the things we've put on the bottom...

-both fork legs already come with rebound springs and the aweshucks mod just includes them for the fun of it? One fork leg comes with a rebound spring and the aweshucks mod adds another one?
-we cut the guide bushings because...the new die spring and rubber bumper are longer than the original rubber stopper? We want more fork tube travel distance?

The die spring and modded rubber stopper reduce the harshness of bottoming out.
If there's only 1 rebound spring, we add another to better control rebounding.
If there's already 2 rebound springs...?
If we wanted a stiffer ride we'd get heavier main springs?

[bigskybassguy]

Sorry, eq, too many ?? for me to deal with. I'm the dumb guy here.

But all I can add to this mod is -- reassemble it using an ADEQUATE amount of grease, but don't overdo it like I did. Because now, I'm always wiping off excess grease that oozes up out of the dust cap, and out of and bottom by the axle. Take it easy with the grease.

[eq]

That's ok. I pretty much got it now; my summary is about right. Thanks for the light grease tip, too.

edit: "about right," but not right. The main issue is, the mod has you buying 2 extra rebound springs to enhance the main springs, not to be rebound springs. There's already 2 rebound springs. The ones you buy aren't for rebound; the rebound springs are just the right size to use to enhance the main springs - that's why you buy 2 of those.

[AweShucks]

rapidshare.com/files/377315982/Front_Fork_Mod_rev._8.pdf.html

Well after a few years without a scoot I'm back in the saddle again. I noticed the link to the guide was dead so I upped it to rapidshare for anyone wanting it. I now have a brand new 09 Met and Ruckus to mod. I haven't checked the supplier links yet in the guide but will edit as needed.

[Dandy Dan]

Welcome back! Good to hear you're back on a scoot.