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Discussion Starter #241
Busy day today, I had my forks completely rebuilt but I couldn’t finish them as I was missing one of the below. I’m pretty sure it was never fitted on one of the forks.

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I decided that I could make one by welding two washers together and cutting a piece out. I raided my dads supplies and found these
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A quick buzz later and 2 became 1 😂
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Next I cut the slot wide enough and hey presto it seemed to do the trick
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So forks all back together.
Next was to attack this
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I have thrown the sprocket as it will be replaced, I fitted the new Cush drives, bearings and got it all back together
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Discussion Starter #242
Part 2!
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I’m using the discs that came on the bike as they are in good nick, it’s a shame to not replace with a fresh set but I have to draw the line somewhere....

I fitted the new head set bearings and slid the forks in
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thats it for today, need to finish polishing the swing arm, get the bearings for the shock linkage then put it all together(y)
 

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That is really super brilliant, Sam. As previously said, I am enthused about the polishing trick.

Would you think the small sets attached to power drills would be efficient enough for swing arm and rearsets? I do not have the space or facilities to set up a bench grinder with wheels. I'm not thinking frame at present, but will 'practice' on VTR components. Am trying to buy a s/h VTR swing arm so I can polish that and then do bearings etc and slip it into my bike. Will then polish the other and slip it on eBay to recoup costs.:D

Anyway, back to yours, very ingenious fork washer you made. Helps to have a good workshop of equipment too. I could fit a welder in my kitchen, but I'd be worried about sparks flying into my fruit bowl and coffee percolator!(y)
 

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Discussion Starter #244
That is really super brilliant, Sam. As previously said, I am enthused about the polishing trick.

Would you think the small sets attached to power drills would be efficient enough for swing arm and rearsets? I do not have the space or facilities to set up a bench grinder with wheels. I'm not thinking frame at present, but will 'practice' on VTR components. Am trying to buy a s/h VTR swing arm so I can polish that and then do bearings etc and slip it into my bike. Will then polish the other and slip it on eBay to recoup costs.:D

Anyway, back to yours, very ingenious fork washer you made. Helps to have a good workshop of equipment too. I could fit a welder in my kitchen, but I'd be worried about sparks flying into my fruit bowl and coffee percolator!(y)
I have tried drills before and i didn’t have much luck, I find that you need a good surface to start with as the polisher even with the coarse wheel can only do so much. I sand it up to 1000 grit and the polish from there. My polisher is not bolted down, it has a stand with a heavy base so you could keep one somewhere and only get it out to use it? I am very lucky to have the workshop that I have, it’s rare that I can’t get round a problem especially with the tig welder. Some sort of metal lathe is my next plan 😬
 

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Those needle bearings are not cheap, and neither is 900RR resurrection, as you are feeling first hand 😂, but it’s an amazing feeling getting that first ride after.
 

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Discussion Starter #247
Those needle bearings are not cheap, and neither is 900RR resurrection, as you are feeling first hand 😂, but it’s an amazing feeling getting that first ride after.
That’s what I’m counting on! My £20 front fairing turned up today, it’s not pretty but it’s complete and seems to be OEM as advertised
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it means I am in a position to find a good paint shop and get all the fairings dropped off. Only problem is I will have to decide what colour I want it all!
 

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Discussion Starter #252
Had a local mechanic fit my tyres to the rims (no damage!) and check my valve clearances, everything was within tolerance so I am picking the engine up tonight. Once the shock linkage bearings arrive I will fit the swing arm, new rear shock and wheels then put the engine back in. It might start to resemble a bike then!
 

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Discussion Starter #253
After putting my forks back together I have found that one of the compression adjustment screws will only screw about 2 turns as opposed to the other that will screw all the way into the preload adjuster before I strip it all down again and waste the fresh fork oil can anyone offer any advice?
 

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How far you screw down the small nut that sites on the washer I believe determines the amount of compression adjustment you get. You can still make it properly I believe without draining.
 

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Discussion Starter #255
How far you screw down the small nut that sites on the washer I believe determines the amount of compression adjustment you get. You can still make it properly I believe without draining.
Thanks Ian, seemed to do the trick, with both nuts set equal the compression adjustment matches top side 👍🏼
 

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Discussion Starter #257
Eventually we'll find something iandoohan doesn't know. Then we'll be in big trouble. 😂
I’ll be stuffed whan that happens! I would have paid someone to rebuild my forks if he hadn’t suggested I do it myself, his knowledge is greatly appreciated!
 

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Thanks gents, I’ve been stumped before, I’ll be stumped again, but’s it’s my pleasure. And @nigelrb, a grind of mine in the states just bought a full Erion system for his 96 for $525. You’ll get that slip on you need matey, it WIlL happen 👍🏻
 

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. . . And @nigelrb, a grind of mine in the states just bought a full Erion system for his 96 for $525. You’ll get that slip on you need matey, it WIlL happen 👍🏻
Yeah, I know. They come up on my 'saved search'. I have seen a few, though not all 929 compatible. I might have to become a tad more negotiable on quality. I know I expect too much for something nearly 20-years-old now, but just like a young woman, they are available and sooner or later fall out of the woodwork!:D
 
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