VJ21 Fork resto

[dusty350]

A quick restoration of a set of forks that came with the spares I got with an Lc recently. These are RWU, VJ21 forks from the first model Rgv250.
They look worst for wear;

20180601_163253 by David Miller, on Flickr

20180601_163317 by David Miller, on Flickr

20180601_163306 by David Miller, on Flickr

Damp has obviously affected the finish on the forks, and the seals leak and the dust seals are totally rotten. Good thing is they appear straight and free from accident damage, and the mudguard is in great condition so that's a bonus. With a couple of project bikes in the shed now I thought it worthwhile to refurb these and possibly use them. I have a pair of 21 wheels as well - the front being a 17" 3 spoke design just like the later 22 model. Oil and dust seals are still available new so I will order those, and it will get fresh oil too, but I thought I would get the worst job out the way today, and clean up the bottoms. I bought a wire cup brush for my angle grinder from tool station to get back to bare ally, and then set up the bench grinder with the polishing mops;

20180602_120236 by David Miller, on Flickr

1 done. Then the other, along with the bottom yoke;

20180602_141243 by David Miller, on Flickr

It's a horrible job, and I was literally black when I finished ! I need to dremmel off the bottom race from the steering stem as it's seized on solid, and then I can give the yoke a better polish, but it's ok for now. Just gotta hope they come apart ok.

Dusty

[andy71330]

They came up great, good condition by the looks of it, here's hoping that they split without to much hassle

[doohanno1]

[dusty350]

Today I stripped the forks down. I couldn't budge the locking bolts that pass through into the damper rod, so a quick visit to my local bike shop, and the cost of a drink saw the rattle gun loosen them off. Back home, I stripped them apart easily enough. Both oil seals and dust seals are completely shot - luckily both still available from Suzuki. Although the pitting isn't in the seal area on the chrome, I'm thinking about a new set of pattern stanchions from Brooks Barn - roughly the same price as a rechrome. I'm also considering uprated springs and oil. When I stripped them I found something odd - 1 spring is different to the other - shorter and coils are different but the spacer tube is longer on that side ? Suzuki part numbers are the same for both sides so seems odd ? Oil was foul too. The shopping list for parts will take it over £400 !!

20180607_145526 by David Miller, on Flickr

I did wonder whether to persevere with them but I have a decent mudguard and bottom yoke which should go straight into an Rd headstock with a 5 quid spacer, plus I have the wheel and discs for a VJ21 and good clip ons too. I'm missing a top yoke but a bit of research on the net hints at a Gsxr400 GK73a may fit. Just bought one on ebay for £16.00 so not the end of the world if it doesn't fit, but fingers crossed it will.

Dusty