Topic: 750F(-1 fork tubes) Progressive Spring Install, Spacer Issue

[Mandic]

While assembling my rebuilt fork assembly I am running into an issue.  The fork setup is a 77 750F with "stock length" fork tubes.  They are brand new -1 tubes from Cycle-X but for a 77/78 750F this is stock length tubes(I compared them to the original tubes and measurements from here).  Now the Progressive springs come with PVC spacers about 1 1/4" in length.  The little note that comes with them says these spacers should be used in a 77 750F application.  However I just cannot get the tube cap nut to start threading.  There is just so much pre-load as I try and squish the o-ring into place and turn the nut, it just doesn't happen.  I took the spacer out and tried it again, with success.  It was still mildly difficult though.

 So my question is, has anyone run into this?  I'm figuring I can assemble without the spacers, ride the bike and decide if I need more pre-load then.  Mostly looking for experience from someone who has run -1 tubes or a stock 750F setup.

[KRONUS0100]

put floor jack with block of wood under motor to unload front suspension.

[KingCustomCycles.com]

I have found a socket and ratchet are the only way to push hard enough, and turn at the same time.  That is, after unloading the forks as stated above.

[Mekagojira]

I had a bunch of problems - ended up using ratchet straps to pull down the socket extender I placed on top of the caps.  Definitely an ordeal.  Totally ghetto - but it worked. Be careful.

The progressive springs eventually eased up - the one that came in my bike ( no idea if they were stock… did not)

[Mandic]

I ended up cutting 2 piece of 1" DOM tubing at 1/2" lengths and putting those in place.  The problem is I installed a set of Coffin Customs, Flat top fork nuts.  So there is no hex to turn with a socket/wrench.  Just one hole I stuck a punch in and turned.  Clean look but difficult on the install process.  Hopefully the 1/2" is enough.  If they get softer overtime or are too soft I will ride for a bit to break in the springs and try again with longer pieces.

The tubes were off the bike, so no loading issue.



And after I assembled most of the parts on the front end last night.