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PostPosted: Wed Nov 18, 2015 7:21 pm 

Joined: Thu Jun 09, 2011 11:25 am
Posts: 3148
Tim, looks like you are having fun with it, looks just like race day. That will be an even nicer bike when you get it all done the way you want it.

One thing I do to any and all new fork seals while replacing them, is to tighten up the tension springs on them.

The procedure is to pull the seal springs out of the seal, and carefully look at the coils. There will be a place on the spring that appears to have one coil missing, an indention. This is where the spring coils are twisted together. Once the spring has been untwisted (just like unscrewing a bolt from a bolt hole), there will be one end with a same size coil straight cut, and the other will have the coils tapering down smaller to the end.

I usually cut off 8 to 10 coils off the straight end, literally shortening the overall coil length, dress the end smooth on my bent sander, and twist the coils back together to reform the coiled tension spring.

Yes, this does increase the tension of the seal face media to the tube, but, I have never had any issues with the mythical "stiction", nor tube/slider drag. All it seems to do is help stop the seals from leaking soon after replacement.

We used to do this same spring shortening method to BMW Boxer engine rear main engine seals after BMW started to disallow warrantee replacement of them. They even trumped up guidelines, in cc's of fluid leakage, "weepage", no big deal, "seepage", "keep an 'eye' on the situation", and, "leakage", "OK, go ahead and replace the seal, just make sure it was actually leaking".

Just more info from stuff we used to do, and still do today.


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PostPosted: Fri Nov 20, 2015 6:39 pm 
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Joined: Wed Jun 08, 2011 5:34 pm
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Location: Front Royal, VA
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Todays progress.

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Tim Steele in Front Royal, VA
Home of the Phoenix Project
Stay in it when it comes on the pipe, no need to be scared...


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PostPosted: Sat Nov 21, 2015 12:13 am 

Joined: Thu Jun 09, 2011 11:25 am
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Tim, that is going to be one great bike. Those things run extremely well, handle nice, stop, and look great. Have you ever seen the last ones from Europe that came with the full fairing? They are as nice as the bike you have started with.

I just finished an engine for one of my RD400 bikes earlier today. It is a 400 air cooled lower end, with a spacer plate under the single liquid cooled cylinder and head. Cylinder, pistons and head are the last series of TZ750 parts, reed valves, and using 39mm carbs. Nice thing about it, it all literally bolts together, only need to use an extra base gasket and make the spacer plate, instant 421 cc's. I modified the clutch cover to use the stock RD400 oil pump, and built a boss/drive for an old style TZ250/350 water pump.

I tried conning Trevor Tilbury into building one of his 3 cylinder RD/TZ cases, barrels and heads for me, but he is not doing them any longer, DRAT.


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PostPosted: Sat Nov 21, 2015 8:57 am 
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I hope to get the forks together today after running some errands and feeding my Baby Mommas. I can't wait to ride it. The 75 RD will be taken out for a run later today. :D :D

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I Love the Smell of Blue Marble in the Morning!!!
Tim Steele in Front Royal, VA
Home of the Phoenix Project
Stay in it when it comes on the pipe, no need to be scared...


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PostPosted: Mon Nov 23, 2015 3:39 pm 
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Found a nice John Deere bearing and sleeve now utilized for driving the upper bushing into place. They now reside in thier new home in my fork seal driver kit. These forks are a PITA to change the seals on. You have to assemble them 1st then drive in the bushing and then some hardware, then the seal and retaining ring....

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I Love the Smell of Blue Marble in the Morning!!!
Tim Steele in Front Royal, VA
Home of the Phoenix Project
Stay in it when it comes on the pipe, no need to be scared...


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PostPosted: Mon Nov 23, 2015 3:42 pm 
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8.5 ozs per fork leg of good old type f.

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I Love the Smell of Blue Marble in the Morning!!!
Tim Steele in Front Royal, VA
Home of the Phoenix Project
Stay in it when it comes on the pipe, no need to be scared...


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PostPosted: Mon Nov 23, 2015 3:44 pm 
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My high tech fork filler....

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I Love the Smell of Blue Marble in the Morning!!!
Tim Steele in Front Royal, VA
Home of the Phoenix Project
Stay in it when it comes on the pipe, no need to be scared...


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PostPosted: Mon Nov 23, 2015 3:48 pm 
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New seals, new boots, new Progressive Suspensions Springs, cleaned inside and out. Polished lowers. Forks done!!! :D :D

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I Love the Smell of Blue Marble in the Morning!!!
Tim Steele in Front Royal, VA
Home of the Phoenix Project
Stay in it when it comes on the pipe, no need to be scared...


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PostPosted: Mon Nov 23, 2015 5:45 pm 
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Tommmorow's plan before work is to reinstall the front fender and wheel and begin building the 3 calipers after I check my Baby Mommas.....

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I Love the Smell of Blue Marble in the Morning!!!
Tim Steele in Front Royal, VA
Home of the Phoenix Project
Stay in it when it comes on the pipe, no need to be scared...


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PostPosted: Tue Nov 24, 2015 2:42 pm 
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Location: Front Royal, VA
Todays progress:Image
New pistons and seals installed. New pads installed.
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Rear caliper built


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Installed and bled (for the most part) lever tied down to burp last of air out. Keep fingers crossed no leaks and no dragging so far....DOT 5 silicone brake fluid is my preference, Advance Auto Parts finest.

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I Love the Smell of Blue Marble in the Morning!!!
Tim Steele in Front Royal, VA
Home of the Phoenix Project
Stay in it when it comes on the pipe, no need to be scared...


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