Getting close to actually assembling parts on this bike project.

What is the best method when it comes to assembling the front suspension?

Should I install the fork tubes to the fork yoke/frame and then added the slider and rest, or should I assemble each fork completely and then slide into fork yoke/frame?

I see advantages to each method.

Cheers

Al

This is in the G3L maintenance manual. Ron

email (option): ronpier@talk21.com

Ron


Thanks for that. I forgot I had the manual in amongst all my PDFs.

I'll print it off and make sure I have it at hand when I assemble.

I noted the requirement to slide on the paper washers.

"An oil seal. (Leather side first.) (See Note below.)
A paper washer.
A fibre (bakelite) bush."

I have all the parts except the paper washers. How important are they? AMC and AMOC do not list them.

There were no washers on my forks when I disassembled them. Anyone know the size (diameter, thickness etc), I might be able to make some.

Cheers

Al

Ron


Thanks for that. I forgot I had the manual in amongst all my PDFs.

I'll print it off and make sure I have it at hand when I assemble.

I noted the requirement to slide on the paper washers.

"An oil seal. (Leather side first.) (See Note below.)
A paper washer.
A fibre (bakelite) bush."

I have all the parts except the paper washers (40-G12M-FF95). How important are they? AMC and AMOC do not list them.

There were no washers on my forks when I disassembled them. Anyone know the size (diameter, thickness etc), I might be able to make some.

Cheers

Al

FF95. I'd just cut them from gasket paper or a smear of silicon. Ron

email (option): ronpier@talk21.com

Ron

The only small issue I see with the instructions is where it says to put the fork tubes in and tap them home with a mallet, then slide on the damper tube and slider assembly.

After assembly, it says (summarised)..

Fit the two oil level screws.
Add oil
Tighten inner tube top domed bolts

and then

"Screw slider extensions to sliders, as far as possible, by hand"

As I have not assembled them yet, I was concerned that there might not be enough slider extension visible to get a good grip considering the bottom cover tube is already been fitted.

The slider extensions I took off had a 8mm (approx) hole drilled through them about 15mm from top end in a fashion that made me think you could slide a screw driver through to make like a "T" handle to facilitate screwing onto the slider.

Cheers

Al

Alun it's a good few years since I rebuilt a couple of sets of these forks and memory fails me a bit. But make sure the threads go together easily before you assemble them and they hang down quite a bit before the weight of the bike is on the ground. Ron

email (option): ronpier@talk21.com