How to rebuild forks on a pw50 (w/6yr old)

Hardtail · 11-25-2008, 08:32 AM

This is meant to be an aid to rebuilding the forks on a Yamaha pw50. I did this with my 6 year old daughter for two reasons, one is just to have fun with my daughter and reinforce the “you ride it you wrench it” law I have in my house. Two is to show how easy it is to do it. I strongly suggest you use a shop manual for this and go by their recommendations for the rebuild. This particular rebuild is based on a 1987 pw50 but Yamaha has not changed the forks on this model. I checked the parts fiche on Bikebandit.com and they were the same for an 87 as on a 03. I used the term rebuild because there are no seals to speak of, except the dust boot on the lower tube (outer tube). This system uses NO FLUID, you only need to clean and re apply grease to the inner components. Dampening is achieved by the use of a rubber “bullet” located in the lower tube. If you are “bottoming out” the forks the springs may need to be replaced or you may be too heavy for the bike. Any grease showing on the fork above the dust boot is just that- grease.

To do the rebuild you will need

Shop manual
12, 14, 17 mil wrenches
12, 14, 17 mil sockets & ratchet
5 mil Allen socket
Needle nose pliers or side cutters (for cotter pin)
Torque wrench Phillips head screw driver
Wheel bearing grease
New cotter pin
Anti seize lubricant (you can buy small packets at local auto parts stores)
Parts cleaner
Shop towels
Wax paper (to lay clean or re greased parts)

You may need
Rubber mallet
Small hammer
Small punch
And a very cute 6 yr old

I will let the videos do most of the talking and have included stills for quick reference, but I would like to add a few things.
Don’t try to pull the snap ring out, instead pull up on the inner tube gently and the assembly will come out.
Have a clean work space and lay all clean parts on wax paper or clean shop towel.
Wear safety glasses when using parts cleaner.
Use a shop manual for recommendations and torque specs.
I used a 5 gallon bucket for a stand, but a lift or true bike stand with a strap to steady the bike would be better.

I left the mishaps in the video because no one is perfect and when you work with your kids you need love and patience. I hope this helps, and remember “You ride it you wrench it”. L.T.R.

Hardtail · 11-25-2008, 08:44 AM

Here are some more pics

turtlemann14 · 11-25-2008, 03:01 PM

you and your daughter are good at doing how to's

TDB303 · 11-25-2008, 03:18 PM

that is some good stuff

Hardtail · 11-25-2008, 03:35 PM

I'm really glad you liked it! I could have done a better job and shortened it, but I was hoping to get other parents to incude their kids in working on their own bikes and this was are first "How to". Any suggestions would be helpful and welcomed. I would like to do more vids with my kids, but I want to do them so it is helpful and encouraging to other parents. Thanks!!

Read · 01-05-2009, 10:08 AM

Seeing you and your daughter working on that bike together is awesome! I just bought a 1987 Yamaha PW50 for my 6 yr old son and he loved seeing your videos. We used them as a guide to re-do his forks. Superb job!

11-25-2008, 03:01 PM	#3 (permalink)
turtlemann14 Pro Mototips Member Join Date: Oct 2007 Location: West Virginia Posts: 4,363 iTrader: (0)	you and your daughter are good at doing how to's __________________ If it does not move at first, get a bigger hammer!! Myspace Yamaha 1982 xj550 under bike lights Kawasaki klx250 1979 custom fiberglass silencer+ Honda xr200r 1985 stock = Dakaw Dk250 2008

11-25-2008, 03:18 PM	#4 (permalink)
TDB303 Super Moderator Join Date: Aug 2007 Location: The Valley, Ohio Posts: 1,809 iTrader: (0)	that is some good stuff __________________ 01 yz 125 District 11 racing http://www.district11ama.com/ http://www.fasttraxxracing.com/ sponsers for 09. THANKS Bo's Radical Racers Moose Racing Boyesen Racing products SIXSIXONE CYCRA racing

11-25-2008, 03:35 PM	#5 (permalink)
Hardtail Pro Mototips Member Join Date: Dec 2006 Location: Southeast V.A. Posts: 2,227 iTrader: (1)	I'm really glad you liked it! I could have done a better job and shortened it, but I was hoping to get other parents to incude their kids in working on their own bikes and this was are first "How to". Any suggestions would be helpful and welcomed. I would like to do more vids with my kids, but I want to do them so it is helpful and encouraging to other parents. Thanks!! __________________ I love the smell of gasoline!! I woke up.....life is good!!!

01-05-2009, 10:08 AM	#6 (permalink)
Read C Rider Join Date: Dec 2008 Posts: 1 iTrader: (0)	Great Job! Seeing you and your daughter working on that bike together is awesome! I just bought a 1987 Yamaha PW50 for my 6 yr old son and he loved seeing your videos. We used them as a guide to re-do his forks. Superb job!

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