While my Bonnie was disabled due to the carb malfunction and I was waiting on the parts to fix it, I decided to rebuild my front forks again.
I had ordered some new parts from Bellacorse that were waiting to be installed:
- Adjustable Fork Preload Caps
- Short Gaiters for Superbrace
- Gaiter Clip Clamps
- Fork Tune & Groom Kit
- All Balls Racing Low Stiction Fork Oil Seals
So, while my Bonnie was up on the floor jack, I removed the headlight, instrument panel and wiring, front wheel, fender and brackets, brake caliper and then the fork tubes from the triple trees. Things then looked like this:
Next, I decided to change the finish of several parts. I ground off the black Plasti-Dip from the headlight bucket and trim ring with a wire bench grinder and decided I liked how the chrome looked like that, and decided to leave it that way for now.
I also decided to grind off the fender mounting stubs on the stock lower fork casings since I no longer need those with my bobbed front fender.
Rebuilding the Front Forks
I followed the process in the Haynes manual to remove and disassemble the fork tubes. Here’s what they look like all taken apart.
I replaced the upper and lower bushings, the copper seals, the upper seals and fork oil using Spectro SAE 15, recommended by Racetech.
For the preload adjusters, I measured the difference height from my stock fork caps and the new preload ones set in their middle position. This told me how much shorter I needed my spacers to be… turned out to be 1/2″ – so I went ahead and cut those down, filed them off and put them in with the new preload caps.
Test Ride to the Peoria TT on Sunday, August 17, 2014
I have to say that with the new fork oil and modifications to the front forks and the new seals in my Mikuni carbs, the Bonnie has never run or handled better. I rode it from Chicago to the Peoria TT and back yesterday, and it performed fantastic.