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Messages - AndyD

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1
Other Bikes / Re: Fork seal removal
« on: July 29, 2021, 09:38:19 AM »
Thanks for replies
Kelly - agreed I'd rather use better ones but the only spare CJ front end I've got has been fitted with 400 stanchions and ones I see for sale often look pretty poor.
I guess the CJ wasn't exactly a much loved or treasured bike back in the day.
I also remember the way we treated our bikes back in the 80's when money was tight so I'm never surprised or annoyed at what I find now when restoring bikes.

Bryan - those odds sound good to me! Even allowing for a lower chance with my inexperienced hands I think it's worth a go.
I'll clean up as best I can then give sealant a go with the new seals.
Could be this was what someone had done previously as well explaining the seals being so hard to get loose.

Cheers,
Andy

2
Other Bikes / Re: Fork seal removal
« on: July 28, 2021, 05:10:07 PM »
Thanks,
Had another go at them today determined to either get the seals out or launch the forks over the hedge!
Finally got them out but not without a real fight.
I think maybe they had been a pain previously and possibly some sealant or glue used to fix them in place as nothing would shift them and when I finally got them out they 'feel' a bit strange on the outside and didn't come out 'clean' at all.
Cleaned up the inside where the seals were and I think someone had used the screw approach previously but very hamfistedly or drilled down the edge of the seals as there are 3 'regular' gouges in one leg as photo.
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The other one had only a single smaller gouge but I did cause some extra damage with a pry bar instead!
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Both fork tops have quite a bit of minor damage where I guess all manner of screwdrivers / pry bars have been used (including mine!).
Hopefully someone can advise if these are still useable - I'm hoping that maybe cleaning up the inner face and using sealant or filler may be good enough to work with new seals but this may just be wishful thinking.
Cheers,
Andy

3
Other Bikes / Fork seal removal
« on: July 27, 2021, 04:12:49 PM »
Almost got the CJ360 completely stripped down and just wrestling with the final few bits.
Footrests for some reason proved really hard to get apart as the pivot pins just wouldn't shift.
On the CJ there's an insert over the pins and these two bits just wouldn't separate until letting the 10 tonne press loose on them - all now safely apart!

Hopefully the very last battle is getting the old fork oil seals out. Normally quite an easy job on every bike I've worked on but for some reason proving a nightmare so far.
Have soaked in penetrating oil, used heat gun, soaked again, used more aggressive heat but they simply don't want to budge.
Even bought a special fork oil seal removal tool but that is no better and starts to bend before anything moves.
The seals are starting to come apart so where the rubber is coming loose I can see the steel rim around the outer edge in one area so I guess there's a thin bit of rubber between this and the fork leg inner face.
I don't want to ruin the legs if avoidable so would welcome any cunning plans to get the seals out.

Cheers,
Andy


4
Thanks all,
Cut each bearing in one side carefully and they came out quite easily.
On to the next part that's fighting back - will start new thread for that!

Cheers,
Andy

5
Good timing - just stripping down the swing arm on the CJ360 which has the same bushes and the old plastic bu**ers don't want to come out easily!
Is there a technique to removing them - no worries about damaging them as they'll be replaced but don't want to damage the swingarm itself.
Cheers,
Andy

6
Other Bikes / Re: Axle clamp stud removal
« on: July 23, 2021, 06:59:02 PM »
Thanks all,
No idea why the new studs are shorter but seems Suzuki just rationalised part numbers on these.
Didn't feel right using them so luckily I've got some spare fork legs and pulled an old stud from one from these to use instead.

Now just got to sort a weeping front master cylinder cover that keeps spoiling the shiny paint finish around it. New cap and rubber seal fitted but still seeps a bit so looks like I'll need to dismantle it and check if the joint face is scratched and needs smoothing off.

Cheers,
Andy

7
Other Bikes / Re: Axle clamp stud removal
« on: July 14, 2021, 11:03:03 AM »
Ted,
They are M8 studs, new one is about 42mm overall and roughly 5mm shorter than the original.

Cheers,
Andy

8
Other Bikes / Re: Axle clamp stud removal
« on: July 14, 2021, 10:00:48 AM »
Well, new stud arrived quickly in the post.
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However the new one has a shorter thread section to go into the fork leg. Part number superseded and has obviously changed a bit over time.
Guess it must be OK but just 'feels' a bit wrong being so much shorter into the leg.

Cheers,
Andy

9
Other Bikes / Re: Axle clamp stud removal
« on: July 09, 2021, 09:09:42 PM »
Ted,
It’s the Laser one I went for.
Probably all much the same but for some reason I still feel some pull to familiar old names!
Cheers
Andy

10
Other Bikes / Re: Axle clamp stud removal
« on: July 09, 2021, 06:22:10 PM »
Thanks guys,
Success ... new tool arrived this afternoon and actually worked just like it says on the tin!
The tool is pretty chunky so may be a problem for studs in confined areas but for the fork stud it worked beautifully.
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Tightened it securely onto the stud and it loosened off surprisingly easily so a real result.
Feels like a tough bit of kit when tightening and grips the stud really well so happy to have another tool in the box!
Just have to wait for the new stud to arrive and I can get the bike back together again.

Thanks for all tips and advice
Cheers,
Andy

11
Other Bikes / Re: Axle clamp stud removal
« on: July 08, 2021, 06:10:35 PM »
Thanks again,
Tried to get the nuts onto the thread but didn't want to go on smoothly due to the mangled end thread.
I've ordered a stud extractor due to arrive tomorrow so hopefully will be a miracle cure!

Cheers,
Andy

12
Other Bikes / Re: Axle clamp stud removal
« on: July 06, 2021, 06:56:21 PM »
Thanks guys,
I'll try the two nuts approach first and hopefully it'll work.
I have no idea how well these studs are normally fixed into the fork leg and whether they are 'easy' to remove - guess I'm about to find out tomorrow when I go back to it.

Cheers,
Andy

13
Other Bikes / Axle clamp stud removal
« on: July 06, 2021, 06:40:01 PM »
Evening all,
Spent the last two days stripping and rebuilding the front end on the GSX1100EZ as there was a weep on one of the fork seals.
Heavy bugger to work on but all went surprisingly smoothly until...
Tightening up the axle clamp nuts and one of the threads stripped at the very end where the nut fits.
I'd like to pull out the old stud and fit a new one but never tried this before and wasn't sure how easy stud removal might be.
Seen a few stud removal tools on Amazon so hoping someone may have a recommendation on which type to use.
The full stud is there with just the last bit stripped so have good thread above that - could try screwing on two nuts as a first option.

Any advice very come - really don't want to strip the front end and forks down again so hopefully can do this in situ.

Cheers,
Andy

14
Desperately Seeking!! / Re: CB400 Neutral Switch
« on: July 01, 2021, 07:10:53 PM »
Daz,
I don't think it affects the switch at all, looks like it's just been removed a bit clumsily in the past.
No charge - you're very welcome to it if it helps you.
PM your address and I'll stick it in the post.

Cheers,
Andy

15
Desperately Seeking!! / Re: CB400 Neutral Switch
« on: July 01, 2021, 03:35:23 PM »
If you're still looking for a neutral switch I've got one here which has a bit of damage to the body but I don't think it affects anything.
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Let me know if it's any use to you.

Cheers,
Andy

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