F800GS Bitubo Fork Kit

Check your PM - I have the rebuild manual.

Passed this on to the suspension guys. Fingers crossed for now.

Special tools are needed (of course), but the shop is making one of their own as I type.
I'm putting a lot of trust in these guys. I probably should just buy the Traxxion setup, but really want to hear what Frank has to say after his big trip first.

Compression stack was "blown apart".
Seems I'm on the road to recovery w/ the Bitubos, but a little re-valving is in order.
I will give a full report when and if I ever get a day off to ride.

a rebuild manual?

http://f800depot.com/articles/Bitubo%20Service%20Manual.pdf

Thanks

I'll be curious to hear how this goes. Are they going to be able to adjust the damping?

I discovered I have an issue with the Bitubo's yesterday. I have a lighter spring in mine, yet don't seem to be getting all the travel available. Been running a zip tie on the tube and it looks like it never gets less than about 2" from the bottom of the fork tube.
Checked the air gap and found on one tube the damping rod will not go all the way down unless I force it the last 2 inches. Kind of grates at the bottom and the rod stick unless I give it a tug, then the gas pressure forces it up.
Still pressurized but I know it is not right. Any ideas? By the way those E clips will not hold the spring guide in place, all have disappeared.

Gary, is the next step Ohlins?

I blew out my fork seal and am looking at options since I'm going to be taking them apart anyway.

David

Yes. Compression has been bumped up.

I am too cheap for Ohlins, I like to spend a fortune on cheap fixes first

Seen a couple of 2004 Husky 250TE tubes for sale and wonder if they could be made to fit.

The weight difference between the 250 and the 800 isn't a problem?

Use the cartridge tube out of it. Respring(got that), revalve, drill and thread a hole in the bottom the 800 fork for the bottom valve and probably a host of other issues to make it fit. But the forks are only $200

So when do you cut and run?

Good luck.

David

When the Bitubos give their last breath of gas.

You INCREASED compression damping??!! :eek1

I want to decrease mine, smooth things out.

Forks are done. Re-built and re-valved.
I managed to break a few shims. I could hear the pieces rattling around when I removed the forks.

I hope to get a ride in this weekend and report back.
The shop I dealt w/ was very cool. They spent a few hours making their own special tools to get the job done. Nice.

Here are some bits and pieces. Easy to see why things didn't feel right.

John,

If you could PM me the shop that you used, I would appreciate it. If you're really happy with them, I'd like to recommend them to folks with Bitubos that are looking to have them rebuilt.

I will post the info here after I get a ride in. I'll be the Bitubo guinea pig w/ these guys.
They are road racers, but didn't shy away from the job. They are also my local Elka distributor. That should be here in a couple of weeks.

Well, all went well today up front. The Bitubos are back in action.
It is safe to say that the cartridges can be re-built and/or re-valved.
It's just a matter of finding the right shop.

http://www.catalystsuspension.com/

714-258-7501

Talk to Tige or James. They machined their own special tools to do this job. I hope they will be able to help out a few others like they helped me.
I plan on servicing the forks every 5,000 miles at this point. Seems like a good number.

I will post more if any problems arise.