Author Topic: -Project Suzzie- (Read 71916 times)

toytuff · « **Reply #300 on:** April 19, 2016, 12:37:24 PM »

Made a left turn and started on other stuff. Trying to find out how to disassemble the forks. We have an air valve and what appears to be a very small ring. No idea how to remove this at this time.

So, let's finish up the headlight, speedo, tach and most importantly new headlight ears with new cushions and trim rings top and bottom. Ah, it's the little things ya know.

Parts!

Needed the forks installed to line everything up, tightened up the top clamp and done.

I need to skip a day. Been hitting this hard. Fuel tank into body shop, very reputable business. Will see.

Later...

toytuff · « **Reply #301 on:** April 19, 2016, 04:56:35 PM »

Just can't stay away!

Done! Push down with tool and dig the ring out. Took many, many tries I might add.

I don't have the proper seal driver but have heard of an inverted socket with extension to drive it in. Good or bad?

I'm sure my friends shop has one but can't get there until Saturday. Would like to get this done.

grcamna2 · « **Reply #302 on:** April 19, 2016, 06:04:01 PM »

A piece of PVC pipe.. I have an adjustable fork seal driver that will work;what size are those fork tubes ?

toytuff · « **Reply #303 on:** April 19, 2016, 07:46:32 PM »

The seal measures 43 mm. No, not using pvc pipe.

Might take the Ducati out for a spin Thursday and run over to Shop in California. I'm sure he has one. I'll send a text tomorrow.

grcamna2 · « **Reply #304 on:** April 19, 2016, 08:07:03 PM »

tt,
I have one you can borrow,send it back when you're done;let me know.

toytuff · « **Reply #305 on:** April 20, 2016, 01:41:11 PM »

Quote from: grcamna2 on April 19, 2016, 08:07:03 PM

tt,
I have one you can borrow,send it back when you're done;let me know.

Dennis said he had one so its a early morning ride on the Duc. Getting hot, damn it. Thank you for the offer.

No time to work on them today. Lower bolts always a pain, might have to impact those off also.

grcamna2 · « **Reply #306 on:** April 20, 2016, 03:45:56 PM »

OK,glad you're guy there has it.

I always hit them w/ the impact gun very lightly just enough to break them loose but not enough to leak.. before(if possible)I even remove the front wheel,etc. and while the front end is still all together,otherwise it's a real pain to brace the lower part from turning w/o a helper while it's all in a bench vise.Those triple clamps sure help to hold the tubes securely.

toytuff · « **Reply #307 on:** April 20, 2016, 04:02:00 PM »

Well, I hope it will work. Wierd seal.

Holding things down not a problem.

Have a 4 inch on the lift table too. Going to throw it in the freezer overnight, get the neighbors 3/8 driver and whack it a couple of times.

The problem is the fact that the bolt its self is recessed so a regular hex socket does not reach. The left is accessible and can be heated.

RAFster122s · « **Reply #308 on:** April 20, 2016, 07:30:45 PM »

So, this is a hex head bolt rather than a hex socket head bolt. Sounds like a good candidate for replacing it with the later might be in order to making service easier.

A good quality socket will be thin wall construction. S&K, Snap-On still make nice thin walled socket if you can obtain one if you don't have one to fit.

grcamna2 · « **Reply #309 on:** April 20, 2016, 08:35:05 PM »

tt,
I think you'll need a helper to 'pull' downward on that fork tube below to put pressure up inside the fork assembly to hold-back some resistance on that lower allen bolt(if you remove the bolt like you have that fork oriented w/ the black 'lower' facing upward)while you're using a 1/2" drive power impact gun to give it a few sharp 'bursts' to break the allen head bolt free.They do get frozen sometimes up inside the forks.Those are most likely the same as all the other 80's Suzuki's w/ a recessed female allen head socket bolt(most likely an 8mm threaded bolt)which you'll need a long allen socket to attach to the 1/2" drive power impact gun.I don't think it will be too tough w/ that but may be if you try using a hand impact driver..

toytuff · « **Reply #310 on:** April 21, 2016, 01:25:59 PM »

Quote from: grcamna2 on April 20, 2016, 08:35:05 PM

tt,
I think you'll need a helper to 'pull' downward on that fork tube below to put pressure up inside the fork assembly to hold-back some resistance on that lower allen bolt(if you remove the bolt like you have that fork oriented w/ the black 'lower' facing upward)while you're using a 1/2" drive power impact gun to give it a few sharp 'bursts' to break the allen head bolt free.They do get frozen sometimes up inside the forks.Those are most likely the same as all the other 80's Suzuki's w/ a recessed female allen head socket bolt(most likely an 8mm threaded bolt)which you'll need a long allen socket to attach to the 1/2" drive power impact gun.I don't think it will be too tough w/ that but may be if you try using a hand impact driver..

I'll finish up right side tomorrow then onto left side.

grcamna2 · « **Reply #311 on:** April 21, 2016, 01:31:56 PM »

That's a nice looking vice you have there in that last pic.

toytuff · « **Reply #312 on:** April 21, 2016, 01:54:26 PM »

Quote from: grcamna2 on April 21, 2016, 01:31:56 PM

That's a nice looking vice you have there in that last pic.

Oh, you mean my overkill locomotive vise? Yeah, couldn't find anything better than what I had so I went to Amazon. Imagine my surprise when this thing arrived!

What the he!! I said.

No place to mount this heavy duty piece of iron. Could barley pick it up. I bought some material, a friend welded it up then some left over spray paint on the post.

Yeah, it's a little much alright but boy can I clamp and crush shid now!

Stev-o · « **Reply #313 on:** April 21, 2016, 02:47:21 PM »

Quote from: grcamna2 on April 21, 2016, 01:31:56 PM

That's a nice looking vice you have there in that last pic.

I noticed that too! I'd like to move mine off the workbench but it's nice to have it mounted to a solid surface.

tt - could yours tip over on that stand?

toytuff · « **Reply #314 on:** April 21, 2016, 03:16:51 PM »

Yes, yes it will. I can bend small stuff, hold stuff, crush stuff but any large work is a no go without a solid mount. Someday I'll have a strong steel bench welded up but for now a 4 inch vise is mounted to the lift table.

Yeah, it's a big boy. 6 inch wide jaws. Made by Yost.

Works great for fork work and locomotive repair.

toytuff · « **Reply #315 on:** April 21, 2016, 03:20:58 PM »

Crushed this the other day.

Retro Rocket · « **Reply #316 on:** April 21, 2016, 04:24:28 PM »

Quote from: toytuff on April 21, 2016, 03:20:58 PM

Crushed this the other day.

I think you can get ointment for that TT....

toytuff · « **Reply #317 on:** April 21, 2016, 04:38:37 PM »

LMFAO!

Good on toast too!

Retro Rocket · « **Reply #318 on:** April 21, 2016, 04:48:38 PM »

Quote from: toytuff on April 21, 2016, 04:38:37 PM

LMFAO!

Good on toast too!

calj737 · « **Reply #319 on:** April 21, 2016, 05:00:50 PM »

Mounting a vise on a pedestal is a very good idea. But, I'd use concrete lag screws and bolt her to the floor. It is how mine is (well, was anyway) installed in my shop. I run a flat stock from the base to the fab table, and ground strap to the table. Then, its always grounded for welding without running cables all over the place. Keeps it neat and tidy (and sturdy too).

Stev-o · « **Reply #320 on:** April 21, 2016, 05:14:37 PM »

Quote from: calj737 on April 21, 2016, 05:00:50 PM

Mounting a vise on a pedestal is a very good idea. But, I'd use concrete lag screws and bolt her to the floor. It is how mine is (well, was anyway) installed in my shop. I run a flat stock from the base to the fab table, and ground strap to the table. Then, its always grounded for welding without running cables all over the place. Keeps it neat and tidy (and sturdy too).

I have my vise bolted to double 3/4" ply and clamped to the work bench. I like the idea of it being "mobile" but it just seems to stay on the workbench and occasionally in the way.

toytuff · « **Reply #321 on:** April 21, 2016, 06:47:51 PM »

You should see the vise down at my friends shop.

Came from the Santa Fe railroad shop. We used it to press the bearings into the swing arm. Huge and the stand even bigger. Used his wrecker truck to bring it over.

I'll grab a picture someday.

toytuff · « **Reply #322 on:** April 22, 2016, 01:20:17 PM »

Well, the fork seal install was a complete fail. Ordering new seals and a damn tool to install them. They are smaller than the seal driver set I borrowed. Enough is enough. Time for something whether I use it again or not. Pipe and other shid just doesn't work.

OK, walk away from that fiasco. Recieved the chrome covers from a GS forum member today.

Before.

After. (Just taped on)

Onward after a few days off from the Shop.

grcamna2 · « **Reply #323 on:** April 22, 2016, 02:16:57 PM »

tt,
I hope you get a pr. of oem Suz. seals(or K&L made in Japan)for it;I just bought a pr. of 'cheap' china seals and installed on a set of forks..

I like the black DOHC covers

RAFster122s · « **Reply #324 on:** April 22, 2016, 04:07:10 PM »

I go for the chrome covers, they will be nice on the silver bike.
Sorry the seals are such a PITA...at least it ain't no CA77 or CA78 with it's constant wrong parts hassles...

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Author Topic: -Project Suzzie- (Read 71916 times)