What was I thinking!…
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If anyone can find a ‘how to’ vid or manual, or anything about dismantling USD 4hw non adjustable forks, can you please let me know. I’m 99% confidant in my doing it on the fly, but I’d rather learn from someone else’s mistakes
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I am lazy but I have looked… -
I’m having real problems finding the guide bush size on the 1993 Tzr125rr 4HW
Both of the bush sizes would be cool if anyone can help! Please…
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I’ve looked high & low. I’m gonna have to sand down the fuxed scraped ones and put them back in. Brooks suspension don’t seem to offer them by size anymore. Not that my measurements were to the tenth of a mm!…
@SpookDog Have you tried Simply Bearings? Those bushes are a pretty common engineering component after all, if you know the dimensions of the stanchion and where they fit, they or another bearing supplier can probably help.
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@SpookDog Have you tried Simply Bearings? Those bushes are a pretty common engineering component after all, if you know the dimensions of the stanchion and where they fit, they or another bearing supplier can probably help.
No I’ve not tried them yet. I’m don’t know what the dimensions are, I can’t find them. I don’t have the tools to measure the existing bushes properly, to the 10th of a MM. i learnt that it matters the hard way last time!
…The fork stanchions are 39mm, the depth of the bush is 20mm, the outer edge looks to be 42mm. I’m guessing the thickness of the bush is a bit les than 1.5 mm, but don’t know for sure and can’t find anything similar…
Edit: nope, can’t even find any bushes on their site
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No I’ve not tried them yet. I’m don’t know what the dimensions are, I can’t find them. I don’t have the tools to measure the existing bushes properly, to the 10th of a MM. i learnt that it matters the hard way last time!
…The fork stanchions are 39mm, the depth of the bush is 20mm, the outer edge looks to be 42mm. I’m guessing the thickness of the bush is a bit les than 1.5 mm, but don’t know for sure and can’t find anything similar…
Edit: nope, can’t even find any bushes on their site
…Inner
Outer
Depth
I can’t find anything even when I search these sizes with ‘guide bushes’
I don’t know what to do …If any web search Jedis’ can help it would be sweet!…
I can’t even get the’search by size’ option to come up @ Brooks suspension anymore!!…
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Inner
Outer
Depth
I can’t find anything even when I search these sizes with ‘guide bushes’
I don’t know what to do …If any web search Jedis’ can help it would be sweet!…
I can’t even get the’search by size’ option to come up @ Brooks suspension anymore!!…
Still no joy with finding the fork bushes. But!
On another subject: This is the clutch side crank spacer that fits inside the clutch side crank seal:
Clutch side crank spacer doohicky:
Are these (two lines) wear marks or are they machined to give a better surface for the seal to ‘seal’ against?…
I don’t know whether to put it back the way it came out because the seals may have different dimensions…On my old dtr lump they looked like wear but these look more ‘purposeful’. Any advice…
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Was there any play in the suspension? I would just reuse those they seem fine to me. Pack some grease in there it'll be alright.
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@SpookDog Yeah, so on the subject of those fork bushes. Is there any reason they need replacing?
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Yeah the Teflon rubbery coating inside is scratched to fux. The stanchions are rust pitted and the sharp chrome edges did a number on them. I’ll take a pic in a bit…
@SpookDog Have you tried Ashley Power in Poole? Depth and stanchion diameter you could probably tell them over the phone but it might be worth actually taking one of the outer fork tubes in to them so they can measure the interference fit aperture precisely as I think this is the critical OD dimension.
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@SpookDog Have you tried Ashley Power in Poole? Depth and stanchion diameter you could probably tell them over the phone but it might be worth actually taking one of the outer fork tubes in to them so they can measure the interference fit aperture precisely as I think this is the critical OD dimension.
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Managed to get the block back together with new seals and crank bearings. The old ones were in perfect condition except for a small dot of corrosion on the bottom of one bearing where it had been sat in the same position for so long…
Got the clutch on and casing buttoned up The inside looks so bare without the kickstart gubbins!…Getting ready to put the newly bored 3MBp barrel and piston on…
Still waiting on the fork seals which appear to have gone awol in the post 🫤 …
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They don't look that bad to me. I have fitted and got away with worse. If you can't locate any, then it might not be the end of the world...
Yeah, I know. It’s just while it’s apart and all…
You should see the stanchions that caused this
…Weird thing: my rotor has something ‘inside’ it that rattles back and forth. Sounds like a single ball bearing or washer, but it’s behind the magnet ring it’s doing my head in. WTF?!…
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Yeah, I know. It’s just while it’s apart and all…
You should see the stanchions that caused this …Weird thing: my rotor has something ‘inside’ it that rattles back and forth. Sounds like a single ball bearing or washer, but it’s behind the magnet ring it’s doing my head in. WTF?!…
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My vastly inferior workbench all ready for my next session
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Ala rebuilt lump/block/butt-end
It doesn’t look much but it has that certain ‘you no say quack’ 
about it. An air of ‘solidity’ in knowing that it’s tight…
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You didn't fancy having the cases cleaned? I used to pop em in the dish washer years ago. Now I get them vapor blasted as the finish us lovely with that.
I really wanted to. I’ve even thought about making or buying a vapour blaster if possible. It’s just time, availability and money. They never seem to come together
…I did it the old fashioned way, with a toothbrush and elbow grease
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Though you wouldn’t think it’s clean to look at it!! But I never put an engine together if it’s got grime and loose crud on it that can contaminate the interior…——————————————————
Edit: Just saw my first SDR200, it’s on fleabay. What a gorgeous little bike!…
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I really wanted to. I’ve even thought about making or buying a vapour blaster if possible. It’s just time, availability and money. They never seem to come together
…I did it the old fashioned way, with a toothbrush and elbow grease
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Though you wouldn’t think it’s clean to look at it!! But I never put an engine together if it’s got grime and loose crud on it that can contaminate the interior…——————————————————
Edit: Just saw my first SDR200, it’s on fleabay. What a gorgeous little bike!…
