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Old 03-14-2008   #1 (permalink)
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Other Motorcycle: '68' T-120R
Question fork tube bushings?

On a 68 T-120R, how tight should the lower fork tube bushings fit around the upper tube. I bought a new set but they seem too tight. Maybe .002 interference fit (they would have to be forced on). Old ones slide on and off by hand with a bit of clearance.
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Old 03-14-2008   #2 (permalink)
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De-burr the edgest of the stanchions, and polish the inner edges of the bushings, they should slide on very nicely with a smear of oil.

Yours sound too tight.
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Old 03-14-2008   #3 (permalink)
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Thanks. New stanchions, old bushes slide on easily, new ones no way. Just wanted to make sure before I reamed the new to fit easily as you described. A lot of the other stuff I've disassembled has required a puller of some sort & I didn't know if this was another instance of an interference fit. Couldn't find any mention in the manual.
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Old 03-14-2008   #4 (permalink)
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Did you get the stanchions & bushings from the same source?
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Old 03-14-2008   #5 (permalink)
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NO! I bought the bushings and a set of stanchions from one source but the top nut and bottom bush nut didn't fit (wrong thread pitch) so I am sending them back (the stanchions). I told the guy before ordering that I thought I had 28 threads per inch or more and he was sure the 68 used 26 threads or UNF "cause that's all Triumph used" so I ordered the 26 thinking he knew more than I do about these old Triumphs. (It is a big, highly recommended establishment) Any way, I bought another set of forks from Frank,s after talking to their tech who informed me the 68-70 did indeed take 28 threads. The caps & nuts screw right on. I am using the bushes from first source because Frank's only sells forks. I checked them on my old forks and they were too tight on them too so I am pretty sure the bushes (& forks from first source) were too small. I improvised a hone by wraping some emory paper around a 22mm 1/2 drive socket and twisted it in the bore of the new bushings until I took out enough so the bush fit tightly on the stanchion then rolled it along the top of my work bench holding a small scotch bright cylinder inside to polish the bore. Slips on nicely with 0 play. Got all excited and assembled one of the forks complete with oil to see how it felt. OOPS I was gonna have the bottom tube powder coated. SO which way does the plastic spacer go on and how long are they supposed to be (the new ones are shorter)? It has a tight end and a loose end. I put it on the way the old one was (with the tight ring to the top) but the fork doesn't seem to have enough damping.
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