refurbing front fork, what parts to buy?

Information relating to the Matchless G80 or AJS Model 18 500cc Heavyweight.
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refurbing front fork, what parts to buy?

Postby rcousine » Mon Jun 11, 2018 10:20 pm

Hi all, I'm trying to rebuild a front fork and looking for advice on which parts I need.

I know the stanchions (tubes) and top nuts are toast on my bike, so I'm ordering those:

022215S (top bolt need 2x)
022823FTK (fork tube kit with seals and circlips)
022216 (top bolt grommets, pair)

I'll do the headset just because:

012620 (top yoke bearing track)
000805 (fork bearing track)
000806 (frame bearing tracks, order 2)
000072 56 balls

I do need the top caps, they were buggered:
021642S (domed forkstem locknut)
021741S (nut fork stem)

Should I get the fork springs, just because? The price is acceptable...
021790

These are things I think must be wear items:
022700 plastic inner fork bush (upper)
021785
021786 leather washers, top and bottom (pair of each?)
021910 rubber washer bottom housing (need 2x)
021911 rubber buffer for fork inner (need 6x)

Anyway, touring through the parts catalogs, I think that's what I need. Is there anything I should add or drop, to properly refurb a front end with bent stanchions?

Thanks,
1958 AJS 18 CS (a work in regress)
Ongoing rebuild photos: https://www.icloud.com/sharedalbum/#B16GWZuqDGvT59n

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Re: refurbing front fork, what parts to buy?

Postby Mick D » Tue Jun 12, 2018 7:21 am

Hi

Consider the condition of the chrome on the bottom cover tubes, it's the ideal time to replace them.

Check all of the threads in the sliders - you may need to Helicoil poor ones.

It's good practice to replace the spring washers on the mudguard bridge and bottom cap fixings.

You'll also need a tool to re-assemble the forks into the steering head - you can make your own from an old dome nut and length of threaded studding or buy one ready made.

Regards Mick

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Re: refurbing front fork, what parts to buy?

Postby Andy51 » Tue Jun 12, 2018 12:54 pm

Given the rapid service the parts scheme offers, why not wait and see what you actually need as you dismantle and check condition? Regarding old fork springs, see that they are a matched pair (same length) and check parts list for correct length- if you are within half an inch or so of correct length they will be OK. Andy

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Re: refurbing front fork, what parts to buy?

Postby SPRIDDLER » Tue Jun 12, 2018 1:29 pm

rcousine wrote:012620 (top yoke bearing track)
000805 (fork bearing track)
000806 (frame bearing tracks, order 2)
000072 56 balls

You will find that there is room for 29 balls in each track. Don't be confused - 28 in each is the correct number.

Should I get the fork springs, just because? The price is acceptable...021790

Your choice, but in my experience these rarely need replacing unless you are a compulsive pie eater or going from solo to outfit or vice versa.

When you go to remove/refit the recessed 'Screw 010697 damper rod fixing bolt' with its fibre washer (you will need a thin walled socket) you will probably find that the damper rod rotates inside the fork slider preventing complete unscrewing/tightening of the screw. This can be overcome by removing the fork leg oil drain screw 000485 and replacing it with the pointy tool box lid screw 014511 which will jam against the damper rod, preventing it from turning.

If you haven't seen it there's a useful article here on teledraulic fork rebuilding.........
http://archives.jampot.dk/technical/Sus ... e_1965.pdf

EDIT
That's odd, the link doesn't work so go here:
http://archives.jampot.dk/technical/Suspension/

Then select 'Teledraulic Fork Overhaul' from the list of articles. (3rd from bottom).
I poke badgers with spoons.

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Re: refurbing front fork, what parts to buy?

Postby rcousine » Wed Jun 13, 2018 3:43 pm

Andy51 wrote:Given the rapid service the parts scheme offers, why not wait and see what you actually need as you dismantle and check condition? Regarding old fork springs, see that they are a matched pair (same length) and check parts list for correct length- if you are within half an inch or so of correct length they will be OK. Andy


This is an excellent question, and their service is indeed excellent.

However, I am in the colonies :). Canada, to be precise, and the far end of it.

So everything gets here and the shipping is very reasonable, but my lag time is about 4-6 weeks depending on how customs clearance is going that month.

I do have the forks apart, but it’s more making sure I actually understand what is a can/should replace at this point in the process.

Thanks for the advice on the springs.
1958 AJS 18 CS (a work in regress)
Ongoing rebuild photos: https://www.icloud.com/sharedalbum/#B16GWZuqDGvT59n

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