Finished the rebuild on the left fork and finished the rebuild on the right fork. Heehaw.
To get the 25mm preload was no problem cutting the spacer to length. The fun starts inserting the top retaining clip on the cartridge above the spring and spacer. I took three of my biggest end wrenches and slipped them in one at a time, between the cartridge rod locking nut and the top spacer washer. My son held the cartridge rod up. Someone mentioned how it would float down, like every time you took your eye off of it. And it wasn't til we got the third hand on it, it was a sinker.
I also screwed the end cap snug on the cartridge rod after getting the spring spacers and washers positioned to help holding the rod extended.
So while my son held the assembly in place, I pushed the spacer down, and grabbed a 21mm wrench, slipped it right in between the washer and rod nut. Then I took the second wrenched, 22mm, and got it inserted under the first wrench, while forcing the spacer further down. I split the first two wrenches and got the third 24mm end wrench inserted. Now I was close to having enough space to install the retaining spring clip. Big wrenches were 1/4" thick.
I got it positioned but couldn't fully slide it all the way with the preload now fully built up. Humm, what to use???
Channel locks. Perfect. SqueezeD the clip all the way across, removed the wrenches, checked the end cap was on and tightened the lock nut against the end cap. Then, extended the upper fork tube up and got the threads aligned and snugged with the end cap in the fork barrel. Was I really done? What an operation. I liked wrestling the clutch assembly more than working the oily forks.
This morning, pumped both barrels and one was evidencing a little fluid bypassing the seal. I removed the dust cover, cut a plastic parts container to make a seal cleaner tool. Inserted the corner of the plastic between the seal and barrel and worked it around the circumference. Then I pumped the barrel again. It was sealing perfectly.
The two forks stood together side by side were within .125" of each other, so I am happy.
Thank you Lord for guiding my hands, and again, thanks for all the support from the members of this forum. Someday, and I hope to actually do a road trip on this machine, in the year 2525........
To get the 25mm preload was no problem cutting the spacer to length. The fun starts inserting the top retaining clip on the cartridge above the spring and spacer. I took three of my biggest end wrenches and slipped them in one at a time, between the cartridge rod locking nut and the top spacer washer. My son held the cartridge rod up. Someone mentioned how it would float down, like every time you took your eye off of it. And it wasn't til we got the third hand on it, it was a sinker.
I also screwed the end cap snug on the cartridge rod after getting the spring spacers and washers positioned to help holding the rod extended.
So while my son held the assembly in place, I pushed the spacer down, and grabbed a 21mm wrench, slipped it right in between the washer and rod nut. Then I took the second wrenched, 22mm, and got it inserted under the first wrench, while forcing the spacer further down. I split the first two wrenches and got the third 24mm end wrench inserted. Now I was close to having enough space to install the retaining spring clip. Big wrenches were 1/4" thick.
I got it positioned but couldn't fully slide it all the way with the preload now fully built up. Humm, what to use???
Channel locks. Perfect. SqueezeD the clip all the way across, removed the wrenches, checked the end cap was on and tightened the lock nut against the end cap. Then, extended the upper fork tube up and got the threads aligned and snugged with the end cap in the fork barrel. Was I really done? What an operation. I liked wrestling the clutch assembly more than working the oily forks.
This morning, pumped both barrels and one was evidencing a little fluid bypassing the seal. I removed the dust cover, cut a plastic parts container to make a seal cleaner tool. Inserted the corner of the plastic between the seal and barrel and worked it around the circumference. Then I pumped the barrel again. It was sealing perfectly.
The two forks stood together side by side were within .125" of each other, so I am happy.
Thank you Lord for guiding my hands, and again, thanks for all the support from the members of this forum. Someday, and I hope to actually do a road trip on this machine, in the year 2525........