Part 12 - Forks (2) Triumph T100R

First step was to build the dust excluder assenblies. This is really just installing seals and O rings. Apparently some time during '71, there were two seal designs. One was a conventional pressed-in single-lipped seal with a sparate "wiper seal" on top of it. The other design was a pressed-in double-lipped seal with a plain washer on top. If you try to order these parts today, (and I've tried it from two places), you get the double-lipped seal from one design, and the wiper seal from the other. Rather than being overly purist, and in the spirit of belt-and-suspenders overkill, I installed both, which effectively gives a triple seal. I made a alignment mandrel to make sure the seal went in straight.

The parts that go into the new stanchions. The shuttle valve is what changes the "stiffness" of the damper from jounce to rebound. I found the new stanchions had some burring around the oil holes on the inside, which made the shuttle motion sort of "catchy". I had to abrade them down.

The restrictor apparently increasingly impedes flow of oil as the suspension nears its full travel on jounce, preventing or reducing bottoming. Texts I have are unanimous that the soft aluminum washer under the restrictor bolt be renewed to prevent leaks. You'll hae to assemble a number of socket drive extensions to be able to hold the restrictor while thghtening the bolt.

Insert the stanchions into the bottom members, not forgetting to put in the plastic damping sleeve.

Then the top bearings, the dust excluder sleeve nuts, and the wiper seals:

Add springs and gaiters, and the forks are ready to go on the bike: