‘66 Monza Jr - Fork Rebuild

[duck749]

Completed the rebuild so I thought I would share info. Originally I wanted to service these to replace the rubber bushing 0278.37.260 from my original post. I was not able to source these so my wife designed and 3D printed replacement. I used a rubber cushion in between fork tube and the upper triple.

The parts I replaced was the felt washer 0278.37.430 using felt washers for battery terminal I found at NAPA. They were perfect ID and OD as long as you removed the smaller washer inside. As far as the seal ring 0278.37.460 I went with standard seal ring 30mmID and 42mm OD off of Amazon. In order for this to fit the lower washer in the aluminum dust cover needs to be knocked out the bottom and replaced through top (above pinch ring). This allows the assembly to go together perfectly!

As seen in other posts I disassembled everything, cleaned, de-burred and polished. The headlight holders and lower fork legs were powder coated. Regarding the rubber 0278.37.480 gasket on the aluminum bushing, I replaced with standard o-ring from Harbor Freight. The reason for this is I think the original being so larger squeezes and gets in threads making it very difficult to remove.

I read that 100cc (3.5oz) oil is to be used, I went with that (20wt) and it filled 1/3 of the leg. When disassembling I only got about 1 oz out of both legs, I assume the lack of oil led to the scratches on the inside. The spring was left as is since I couldn’t source any and Sonic or RaceTech couldn’t custom make any.

Back together now and waiting on replacement rear shocks which I found reproduction covered ones from Triumph to maintain similar aesthetics.

[duck749]

More pics.

[Kabi]

Hi duck749,

glad someone appear with similar Monza i have and dealing with the rubber piece as I here : http://www.motoscrubs.com/forum/viewtopic.php?f=3&t=3264
May i ask you if is possible to get an .stl file with the part?
If so, it will be epic and i can continue with assembly.

Thank you,
Jan