how do take this fork assembly apart??? 1970 tc120r PIX!

AliBenn

here is the dmg:

AliBenn · Posted: Fri May 16, 2008 8:13 pm Post subject:

forks off bike

AliBenn · Posted: Fri May 16, 2008 8:18 pm Post subject:

appears tht #4 on expanded diagram comes off some how
pressed?
twist?

totally off base?
thanks
steven

jayel · Posted: Fri May 16, 2008 8:54 pm Post subject:

allen headed bolt up from the bottom, you'll need a air impact wrench to spin it out if you try to loosen it other wise it will just turn in the leg, know a gas station that does repair work? have them remove them oops took another look at the drawing think there's a clip ring at top of the fork leg #8?

AliBenn · Posted: Fri May 16, 2008 9:07 pm Post subject:

took pix of bottom
only bolt is fork oil drain cap
~
also found this pix
looks like it is pressed
~
you the man J!!!

AliBenn · Posted: Fri May 16, 2008 9:12 pm Post subject:

we started to bang the crap out of the lip of part#4 (this could be #9)
not messed up yet but the standard screw driver will cut into part #4 if we hit too much harder
~
part#8 appears to be a rubber cir clip but unk how to remove without ripping 40yr old rubber\
plz see 4th pix posted of this rubber cir clip
~
BTW the fork tubes look/feel pretty stout.
i dont think i have the tools to do it.
if i can dis-assemble the forks, maybe can get a machine shop involved

found dealer tht lists the fork tube for $39.82
possible might be avail.....but still need to dis-assemble

jayel · Posted: Sat May 17, 2008 5:26 am Post subject:

this is the circlip you need out pry one end in and try to get under it with another small screwdriver to start lifting it, looks like it will need to pull the seal out too may be just sliding the tubes will bang them out but if you're having trouble take them to a shop with them off the bike you've already done the hard work

AliBenn · Posted: Sun May 18, 2008 4:12 pm Post subject:

looking at manual i have
found this:

tool#19 is a fork outer tube nut tool
appears tht special tool is needed to remove bent inr tube?

there is no way to take out seal w/out destroying it
(appears tht is a seal only not a clip

jayel · Posted: Sun May 18, 2008 5:29 pm Post subject:

ouch looks like thats right, you could try a strap wrench or find a old suzi dealer that might still have that tool

AliBenn · Posted: Sun May 18, 2008 5:49 pm Post subject:

seeing how it is so old, might try harley dealer by my work

cant figure out how the #19 tool works
clamp on and bang the tool until the pressed nut comes off?

will keep everyone posted

jayel · Posted: Sun May 18, 2008 6:11 pm Post subject:

looks like the top of the lower leg is threaded, so the upper would be threaded internally probably setup harder than the hubs of he!! after all these years maybe a little heat would help, take it to the dealer and take along a print out of that diagram they might be willing to help if you've done the homework on how it comes apart

AliBenn · Posted: Tue May 20, 2008 7:22 am Post subject:

went to harley shop near work
the fork nut was threaded on outside.
old bearded mechanic came out
he placed the bottom of the otr tube in a vise(where axle nut goes thru)
took on of those craftsman rubber strap tools(to open pickle jars/rusted faucets/etc)
and strapped it to the nut and turned......came loose.
hooray!

not need to see if suzuki has inr tubes avail
if not, mechanic said try this:

http://www.frankmain.qpg.com/

until next chapter

AliBenn · Posted: Tue May 27, 2008 8:26 am Post subject:

inr tubes discontinued per suzuki
emailed fork place.......

AliBenn · Posted: Thu Jul 17, 2008 10:54 am Post subject:

wow
have been searching and searching

found used assmys in oregon $175 plus like $50 shipping
the place wont send me pix of these forks(could be wrong parts or crap parts)

then was referred to this vintage bike recycler/New Old Stock shop in Conn.
by ellen @Reproduction Decals www.reproductiondecals.com

Paul Miller Motorcycle. His phone number is 860-828-1220
jeff had all the NOS parts i needed

so seals/inr tubes/inr washers/shipping $150!!!!

will take pix after bike fixed