front fork questions

[jleewebb]

I could use a little help here, experts. The front forks on my '62 cb77 rider leaked just a bit after I reassembled the bike. I blamed it on using old o-rings when we replaced the main seal. and lived with it. I eventually found and ordered the o-rings a while back. Beautiful day, finally got around to trying to replace them today.

What's got me stumped is the 40.5x3.0 O-ring, #15 on attached from parts manual, #18 from service manual. Part # 34672 51522-268-0000. Parts manual is unclear, service manual seems to show it below the lip on the brass front fork pipe guide (#19), where the bottom case would snug up against it. That seems to make sense but doesn't feel right somehow. Disassembly photos show no o-rings there when I took it apart. Plus the bottom case doesn't want to screw into the chrome seal housing; doesn't want to go up in there far enough for the threads to catch.

So question #1: where does that o-ring go?

Question #2, once I get that figured out: The springs are apparently progressive, coils further apart on one end than the other. Does the end with the coils close together go at the top or the bottom of the assembly?

I'd really appreciate some expert advice here. It says "advisor" over there on the left, but I'm really just a rider and a reluctant and often ignorant wrencher.

I you double click on the "manual" pix you should be able to see them better.

Thanks a lot. --Lee

[FAST FRED]

Lee on my 65 CL77 with steel lower fork legs the O-ring fits into the seal holder in a grove just above the threads and about 3/8" below the seal.

Fast Fred

[jleewebb]

Thanks Fred;

I went ahead and pulled the tubes out of the triple tree so I could get a good look at the inside the seal and there is a groove more or less where you described. When I moved the o-ring over to upper side of the guide piece and slid it up in there, the o-ring fit right in the groove. So I'm gonna assume that's where it goes. No sign of an existing o-ring there, apparently I just messed up reassembling.

So I guess that's one place where a cl is at least similar to a cb. If anyone with cb-specific info would care to chime in, even if just to confirm this, it would be reassuring and greatly appreciated.

So if I can get an answer to question #2 now, which end up on springs, I'll be ready to put it back together.

Thanks! --Lee

[ricksd]

It doesn't matter which way you put the springs in, tight coils up or down the springs will react the same.

[jleewebb]

Thanks, Rick, that's what I needed to know...I'll stick both springs in with the same end up, anyway just for consistency.

And thanks, Fred, the more I think about it the more obvious it is to me that your suggestion is exactly where those o-rings go. I threaded one of the lowers on with no spring on a trial-fit basis, and I could feel it tightening up against the o-ring.

Looking forward to clean front forks. Can't believe it didn't leak more with no o-rings in there, what a dummy.

Thanks again, friends! --Lee