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Airone fork rebuild

Discussion in 'MonoCylindrico' started by GT-Rx®, Feb 16, 2020.

  1. GT-Rx®

    GT-Rx® Administrator Staff Member GT di Razza Pura

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    I have been asked to find out about the reassembly of the airone forks. My friend has one that was all apart when he got it. He has a bad reprint of a parts manual I think and he is a capable mechanic but the bike parts don't match the manual picture. He's not a computer guy though hence me asking the questions. Not sure what the actual year his bike is though he does have the rear hydraulic shocks.

    The part in question is on Tav. 12 ,,, part # 25 ,,, the long rod … his rod doesn't have the round disc attached to it and no signs of one ever being there same for both sides.... has anyone else discovered this? and is it an issue for reassembly.

    Tim

    aironetwo.jpg
     
  2. GT-Rx®

    GT-Rx® Administrator Staff Member GT di Razza Pura

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    Hi Tim,
    I have a damper assembly on the bench at the moment and have attached a couple of photos
    The disc on the rod appears to be solid to it, above the disc the rod tapers to a smaller diameter for some inches and then tapers back up to size again
    This tapered section almost closes the orifice in the damper body at either end of the travel restricting the oil flow
    At the bottom end of the rod items 20-24 assemble to make a spring loaded one way valve allowing oil to flow upwards through it during fork compression
    restricted by the spring pressure
    21 is a reasonably tight sliding fit inside the fork sliding leg
    19 is a rubber seal on the bottom of the damper body and a tight sliding fit inside the slider
    15 is a seal at the top of the damper body sealing the rod it is retained by a thin steel washer peened into place
    I would think that the disc on the rod is there to keep the rod from deflecting sideways from hydraulic pressure during fork compression

    I had the loan of a set of Airone forks to get me back on the road while mine were getting re hard chromed so could compare them to the 500 GTW that I own
    There are a couple of differences between them,
    The brake side slider has smaller axle bolts
    The springs on the Airone are lighter,(shorter?) and the short springs at the top of the forks are shorter as well
    The damper rod is shorter by he difference of the top springs

    John O Regan

    20200216_190529.jpg 20200216_190431.jpg 20200216_190448.jpg
     
  3. GT-Rx®

    GT-Rx® Administrator Staff Member GT di Razza Pura

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    Hi, there are a few videos on youtube dealing with Airone forks.
    One deals with stripdown:


    And there is a 3 part video describing a fork rebuild, the link for the first part is:


    The second part:


    The third part:
     
  4. GT-Rx®

    GT-Rx® Administrator Staff Member GT di Razza Pura

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    Hi Tim and All,
    I got a few minutes to measure up the disc on the damper rod earlier
    It is positioned with its lower edge 66mm from the very end of the 6mm threads at the bottom end of the rod
    It measures 4.7-4.8mm thick and 24.4mm diameter (the same as the valve body at the end)
    It has 8 x 3.5mm holes drilled through it (these are larger than the holes in the bottom valve)

    I looked at Paul's video's too
    On Paul's bike's damper bodies it looks as though a previous attempt to fit the seal retaining washer was very heavy handed ?
    I was able to pop out the washers to fit new seals,
    I bought a kit on ebay but it had been opened previously and was missing one or two bits
    I got a company locally to make new seals for the bottom of the damper bodies
    The damper bodies on my GTW had been over tightened and the threads damaged
    I made a "tap" to clean up the threads in the legs and was able to clean up one damper body
    The second one had to be clad welded to build it up then turned to size and thread cut

    I bought new rollers and slider blocks from Italy, had new hard chrome on the legs
    I made new fixed bushes for the upper end
    So almost everything needed attention !!!!
    I still need to correct the offset on the front wheel as it is about 10mm to one side.

    John
     

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