tubes and springs

[preston]

Scout:
i would use the adjstable preload (if forks are in good shape ), use the entire newer forks.
clean them.
drill them per Minton Mods ( just google Joe Minton XS mods )
clean them, and re-install,,, i used 223 CC of 15 wt fork oil (each side)
I did this,,, on my 75 bike, which now has 81 forks.
I have a 77 ride, which was my base line ( those forks, have never been apart, at least by me, in past 14 years)
My new 81 forks, I rode in the "soft' position, and they were fine,,, but cushy.
I twisted the screw down to push on the springs, and it actually rides very nice, no complaints. (and not too harsh)
I did not replace seals, or dust covers.
Cost $.00.
Ride, Priceless.
PS, if i can lace up and true up a rim , you can do this.
Preston

[5twins]

I think the Minton Mods are worth the effort. According to the original article, the stock forks are pretty good but don't respond well to little bumps or the 1st initial bump in a series of bumps. I noticed that on mine. The Minton damper rod mods help with this. So yes, I would recommend swapping the springs and top caps from one of your later sets into the '77 forks and modding the '77 damper rods, also one ounce more of oil. Oil weight will probably take some experimenting. I would try both 15 and 20. I plan to do that eventually. So far I've only used 10.

Another little mod you can do is to add the little top out springs from the later forks to the '77 set as it has none. Forks rarely top out while riding but every time you centerstand the bike they will. On a '77 you may notice a "clunk" or click when you do so. This is the damper rod top hitting the fork tube bottom bushing assembly. Adding the little top out spring will eliminate this full-on hard metal-to-metal contact. It has the additional benefit of adding a little bit more preload to the fork spring. The amount is not as much as the photo would imply as the top out spring gets compressed to about half it's free height once the forks are assembled .....

[scout4924]

Thanks guys, I hope to get at it soon. I may just pull the main springs and caps off the 79 rather than pulling the lowers off to get at the top-out springs. I won't have a centerstand on the 77.