OK, Let's get busy with the fork strip... this is all done following the instructions from the Husaberg WP Extreme manual linked on the first page.
Remove the top:
Here are the innards, the black plastic tube is a 3.5" spacer that I will be removing from the comp side, and replacing with a different spacer on the rebound side to limit the fully extended length. This will be a temporary measure to make the forks similar in length to the stop forks until I extend the swing arm and go back to full length. I haven't made any calculation and haven't planned on changing the springs and valving... I will only be shortening the length to do some testing.
And the correct order and orientation of those bits:
610 mL's drained from the tube:
Oops, the lower washer that is below the spring fell out while draining the forks the manual is very specific that the orientation of this washer should be carefully noted!
So here are all the bits:
Next, remove the lower bolt to release the damper. I used the axle to hold the leg while removing the bolt.
Extract the damper mechanism
See that aluminum wheel at the top? It has to be unthreaded to allow access to the return spring where the new extension limiting spacer is going to go... the manual shows this fancy tool that I don't have and am not going to buy.
The first attempt to make a adjustable pin spanner involved an old crescent wrench and two drill bits, stolen from last month's Classic Bike magazine:
After dulling and sharpening a number of bits, a number of times and not making any headway (use, I used copious oil to cool the bit) I changed it up and used an old rear shock spanner
That quickly bent
I didn't want to clamp the tube in the vice, so here is what I did, I ended up using another c-clamp on the other end of the screwdriver with a small block of wood to hold everything in place
Version three... another shock spanner, but twice as thick as the version 2 version
That with some heat did the trick! The spacer is going to go below that spring and will reduce to total length the forks can extend to.
So, now I need two sections of tube that have an OD less than 21mm (edit - 20.0mm to 20.3mm fits well, closer to 21mm does not) and an ID larger than 12mm. The closest thing I could find at the local hardware store is 1/2" schedule 40 pipe. It is a starting ID of ~15.3mm and an OD of ~21.4mm
Now, I am trying to figure out the easiest way to turn down the OD of the schd 40 to 21mm without a lathe.... more later need to eat some lunch.