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Fork rebuild problem

 
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debby



Joined: 15 Apr 2004
Posts: 898
Location: Boulder, CO

PostPosted: Sun Nov 14, 2004 9:49 am    Post subject: Fork rebuild problem Reply with quote

I'm moving forward with my disk brake conversion project and have been working on assembling the new forks. The fork tubes (stanchions) are new "british made" units I bought from an ebay merchant. The new bushings came from England. But they don't fit! Or more precisely, both the upper and lower bushes are a press fit onto the new fork tubes. And the lower bushes are a very tight press fit onto the fork tubes. Talk about stiction! Shocked

According to my vernier calipers, the new tubes have an OD of 34.5mm, the same as the old ones on my bike. So it looks to me like the bushings are sized wrong rather than the tubes being too big.

Is this normal? Should the assembly instructions include "ream the bushings to fit" (or maybe work them with emery cloth etc) or did I just buy some crappy bushings?

Debby
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illf8ed



Joined: 30 Dec 2003
Posts: 475

PostPosted: Sun Nov 14, 2004 1:44 pm    Post subject: Lower stanchion bushes Reply with quote

Hi Debby,

It's not just you. The Brit made stanchions have had this problem for nearly 10 years. I don't know why they don't fix it. I had to use some dry wet sand paper with a little oil to slightly reduce the bush area of the tubes. After that the whole assembly went together fine.
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Ron L



Joined: 27 Feb 2004
Posts: 1151
Location: Ohio

PostPosted: Mon Nov 22, 2004 8:07 am    Post subject: Reply with quote

I don't think it's the stanchions. 34.5mm on a 35 mm spec should not be too large. This seems to be a problem with a number of replacement bush kits. I have a couple sets of bushes which don't fit any tubes I have. I have tried them on a new set of Frank's tube, a set of tubes from Les Emery (Norvil), and a set of unused +6" chopper tubes. The bronze top bush is too small in ID to slide freely on the tube and the steel bottom bush is too large in OD to fit in the slider. One of these sets came from DomiRacer and unfortunately, I know of several others with the same problem with their kit. The other set came from either RGM or Norvil. I plan to cajole a friend with a lathe into turning down the steel bushes for me when he cuts the +6" tubes down to stock length. I'll probably hone the bronze bush with a brake hone.
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debby



Joined: 15 Apr 2004
Posts: 898
Location: Boulder, CO

PostPosted: Mon Nov 22, 2004 9:29 am    Post subject: Reply with quote

My bushing kit came from RGM and it's exactly as you describe Ron. In addition, the lower bushes don't fit on the new tubes. The old forks are still together so I don't know how the old bushes fit on the new tubes etc.

Debby
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jimboyle



Joined: 11 Aug 2003
Posts: 32
Location: Glasgow

PostPosted: Mon Nov 22, 2004 10:19 am    Post subject: Reply with quote

I also rebuilt my forks, new stanchions, new bushes etc. Still really sticky, i did all the mods as listed in previous posts, then bought an RGM fork brace and spent hours trying to get it to fit.

Still hopeless so i have given up.

On Saturday i bought a used set of forks and yolks from a Kawasaki ZX9R and will somehow get them to fit.

They are from a 1998 model and have the same general overall appearance of the Commando forks so apart from the stanchion diameter of 46mm should hopefully look reasonably OK

Jim
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The Unapproachable Norton Commando

At the end of 1967 the Norton Commando was announced.

The Norton Commando was greeted with a certain amount of scepticism because on first sight the commando appeared to comprise of the old Norton Dominator twin cylinder engine mounted at an inclined angle in a set of new cylinder parts.

It was not realized that the new Norton Commando Isolastic method of engine suspension damped out all engine vibration and produced a machine which had uncanny smoothness for a vertical twin. In due course the critics were silenced and the Norton Commando had the distinction of being regarded as the first of todays so called superbikes. There can be little doubt that the original design concept of the Norton Commando has proved correct, since comparatively few modifications of any real consequence have been made since production commenced during 1968.

Now nearly 40 years later Norton Commando riders like us are a breed of our own, and as far as we are concerned its still more fun to go for a blat on the old Norton Commando, and fast. As a Norton Commando owner and enthusiast, my goal here is to promote and give credit to those who keep the Norton name going.

It is more deserving to give credit to the Commando itself, for after all these years it continues to be respected. The original Commando designers like John Favill are those who deserve the credit for developing this incredible motorcycle.

The Norton Commando Roadster and Interstate of the late seventies, never died. Although the Norton Villiers factory dispersed the tradition lived on. Today Kenny Dreer in the USA is developing the new 952 CC Norton. What a great looking bike this is, and its engineering is still based on the original layout. It will be interesting to see how the new 952CC Norton does in todays tough motorcycle market. One thing is for sure, I would own one if I could afford it.