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2008 DJ 1 fork rebuild questions

pnj

Turbo Monkey till the fat lady sings
Aug 14, 2002
4,696
40
seattle
I have only taken one other fork apart. It was a DJ 2 from around 2002. was pretty simple...

I now have a DJ 1 that came on my STP. It is a 2008.

It is completely locked out and someone said it was due to dirty oil. I can't seem to find a decent manual but am not afraid to go at this thing blindly.

with that said, any suggestions or directions would be nice. :)

Is there only oil in one side of the fork? if so, which side and would dealing with only that side help/fix my issue?

Thanks!
 

Mike87

Chimp
Aug 8, 2011
16
0
Hauser, Idaho
Think of it this way. The fork does not work now, so if you modify it and it still does not work, you are in the same boat, but if it does work, you just gave it new life for relatively little effort. If it does not work, then you still have to get a new fork.

You can call some fork rebuilders and see if they can fix it. More than likely they will want to sell you a new cartridge (if it is available).

Good luck,
Mike
 

pnj

Turbo Monkey till the fat lady sings
Aug 14, 2002
4,696
40
seattle
one of the shops wants to charge me 80 bucks to do the 'open bath' thing. I'd rather spend money on whatever tools I may need and do it myself.

Does anyone know what size socket fits the nuts on this fork? I need to buy some thin walled sockets because the ones I have won't fit between the nut and the stanchion. I didn't see the sizes listed in the manuals that were posted above.

Thanks.
 

pnj

Turbo Monkey till the fat lady sings
Aug 14, 2002
4,696
40
seattle
turns out I had a 12 that fit. Did the surgery on my fork last night. feels good but I don't have a pump so I won't know how it really feels until I put some air in it.