My RC24 resurrection

Doh! Just read your post to the end! Thanks!


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So ended up drilling the bolts out ok. Took my time and no major issues. Got the dust seals off and water had got in, so the retaining clip on the left fork was badly corroded. Someone in the past had tried to get it off and it had broken. Got it out after a bit of mucking about. But then couldn’t get the slider and stanchion apart. The oil seals were stuck fast. Didn’t want to do any further damage so I’ve taken the easy option and I’m handing them over to a company to sort out. Nevermind, have it a go.

Also have had the front wheel stripped, ready to powder coat at the weekend.
Slowly getting there.






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I can't believe you were able to remove that from the broken circlip from the fork. Bravo. This gives me nasty flashbacks.

 

Thanks mate! Tbh, it was so far gone that the metal was pretty weak and after a bit of tugging, I was able to use the circlip pliers to bend it up and out.

There’s some pitting at the top of the top. Not very much and not where the seals will slide, so hopeful that they won’t need re-chroming.



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I try and switch over to this style when I can. Easily removed with a screwdriver or pick.

 

As long as it's not in the seal swipe area, it's just cosmetic. Even some very light sporadic pitting the seal area is not a show stopper, you just have to make sure you stone down any high spots. CLOSELY examine your forks in the critical area for dings or pits that need to be knocked down. It's the most common reason for failure after new seals, with plain old poor workmanship behind it. It is rarely the seal itself, as everyone likes to blame them. I've used a number of aftermarket seals with zero issues, as well as OEM, and I've never had to take a fork back apart for a leaky new seal after the first few rides.

 

If you have the circlips out and bolts out of the bottom then the only thing stopping you from pulling the legs apart is the bushes jamming against the old seals, give them a good soak with WD40 and use some effort to slam the compressed stanchion up ….

I assume you have removed the anti dive from the left leg

 

It also might help to apply heat to the upper forks where the seals are... nice and hot so you can't touch it.

 

Thanks guys. Thumbs, yes, I’d dismantled the anti-dive. I thought about applying some heat but didn’t want to make things worse. Anyway, taken the easy option and packed them off. Hopefully I’ll get back a much improved set of forks.


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I’ve got a week’s holiday the week after next, when I’m hoping to get the majority of the front end rebuilt. At the very least, I want to get the forks back on, bars and controls. So today I’ve just tried to tick off a few jobs, ready for then.
First job was to rebuild the front brake master cylinder. Is dismantled it a good few weeks ago, so it took a while to get my head around it. All sorted bar for the fact I think the pivot bolt isn’t OEM, so I’ve got a new one on order.





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Next job was to start running down the nose fairing. I’d repaired the major cracks and a missing piece a few months ago, but I’d had no reason to touch it since. So I got some 240 wet n dry paper and removed the ‘cam gear train’ and front ‘Honda’ decals and then gave it a rub all over, to start getting a ket on the surface for when I get it resprayed. There’s one deep chip on the front that I will need to get a little filler in, so I’ll buy some tomorrow.



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While I had all that out, I started having a go at the windscreen, which was filthy and had been covered in decals. I spent a while with a plastic scraper, removing them, including an original Japanese market decal that has started to bubble. No idea what it was on there for.

I used 800 and 1200 grit wet and dry then have it a T-cut. I’m not happy with it, so it will need a lot finer grade of paper.


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Last thing was the speedo cable gearbox, which was covered in gunk. Gave it a good flush out with GT85 before cleaning the nylon gear and lining the worm gear. I noticed that the machine screw which secures the cable has sheared in the housing. It doesn’t look like there’s much in there so I’m hoping it should drill out and clean with a tap relatively easily.



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Spent a bit more time filling cracks and sanding back. Pretty pleased with what I’ve done so far on the nose fairing. Now need to spend a bit of time on the main side panels. Front brake calipers now in the post to be refurbished.




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A good few hours of filling, sanding, priming, more sanding and filling. Pretty pleased with the finish I’ve got, so far. Front wheel is ready to be picked up from the powder coaters and I’m hoping I will have the forks back by the end of the week.



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Hello, what putty do you use, nice restoration.

 

Isopon 38.


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Thanks You

 

Had quite a break from the VFR, mainly due to life getting in the way and also losing the spring from the anti-dive unit. Finally managed to get a replacement, which meant the company that I had sent the forks off to were able to complete their refurbishment. I got them back yesterday along with new seals in the front brake calipers. I should now be able to start getting the front end rebuilt over the next two weeks.





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