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D1 front fork movement
Second Gear User
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January 12, 2019
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July 11, 2019 - 7:18 am
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I have a D1 plunger GPO that I'm restoring, now the thing was in bits and most parts missing when I got it. I'm rebuilding the forks and notices there's quite a bit of play on the lower fork legs, so new bush's, exactly the same, so got them on the micrometre, and the bush's are almost exactly the same. My attention then went to the fork legs (thought they may have been worn) and the measurements are equal all the way down. This is my first Bantam, and I'm used to working on telescopic forks, but surely this isn't normal. Its a 1963 bike, but I think nothing is original on it, so no idea what year the forks are, apart from them being plunger rather than rigid forks. 

steve morrison
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June 13, 2019
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July 11, 2019 - 9:59 am
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Hi Megga.

I've just renewed bushes in my front forks 1959 plunger frame D1 and they have turned out fine as matter of interest what is the dia of your lower fork legs if like mine they will be chromed and just over 1" and very snug fit into the new bushes in fact I gave mine  a light primer coat of paint but had to remove as it made them to tight in new bushes.

I'm not sure but think very early D1 had slightly smaller diameter front forks sure some one on site will correct me if this is incorrect.

Cheers Steve

West Norfolk
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July 11, 2019 - 7:51 pm
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If you have lots of play there is a good chance that some of the bushes are missing. The spares book diagram makes it look as though there is only one bush in each leg and in some sections of the parts listings there is an error listing a total quantity of 2 per bike when it should be 4.

The fork bushes for all D1's & D3's should be the same.

The only differences are that the very early forks had the top bush soldered in place, all other forks had a retaining ring for the top bush to butt up against, then a spacer fitted, the second bush then the retainer screwed to the bottom of the leg to hold it all in place.

The D3 forks still used the same internals but the upper outer leg tube and yokes were a bigger diameter to increase fork rigidity.

I recently learned that although the D5 parts books show a similar looking lower leg they used a different lower leg number and were probably of a slightly different design, but in other respects are similar to a D3, including the same bushes.

I'm not a complete idiot ............................................ some parts are missing.

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