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#406349 - 11/30/11 3:31 am Converting 1965 T100 Forks to Shuttle Valve Type  
Joined: Feb 2008
Posts: 4,050
Tridentman Online content
BritBike Forum member
Tridentman  Online Content

BritBike Forum member

Joined: Feb 2008
Posts: 4,050
New Jersey USA
I am currently restoring a 1965 T100SR. My concept of restoration is not "as it left the factory" but rather "it looks original from 20 feet but incorporates improvements wherever possible"
I wanted to convert the forks on this bike to the later shuttle valve internals.
I referenced the following parts lists:
#6 (1965),SPC2 (1968),SPC8 (1969),56-00290 (1970),99-0902 (1970)and 99-0903-2 (1970).
To anyone contemplating doing this here are the details:
First the good news---things that dont need to change:
a) Bottom members (H1842/3--97-1842/3)
b) Cork washer (F4047-82-4047)
c) Spring abutment (H1657--97-1657)
d) Gaiter (H1645-97-1645) but can use the later 97-3635.
e) Spring (H1891--97-1891)
f) Plain washer (H1656--97-1656)
g) Oil seal (H1500--97-1500)
h) Dust excluder(H1654--97-1654)
i) Plain washer (H431--97-0431)
j) Top bush (H441--97-0441)
k) Damping sleeve (H1896--97-1896)
l) Lower bearing (H443--97-0443)
m) Aluminum washer (H1062--97-1062)
Now it gets more expensive! The parts needing to be changed are:
a) Stanchions (H3904--97-3904) the hole drilling is completely different from the original (H1890--97-1890)and the threads at each end are changed from 1 1/16" 26 tpi in the original to 1 1/16" 28 tpi on the stanchions with the drillings for the shuttle valve operation.
b) Cap nuts (H2245--97-2245) (changed thread to fit the new stanchions)
c) Bearing nut (H2091--97-2091)(different design to accomodate the shuttle valve and different thread to fit the new stanchion).
d) Restrictor (H2090--97-2090) Different smaller shape to fit inside the shuttle valve. Also different internal thread---1/4" 28 tpi compared with 5/16" 22 tpi on original
e) Flanged bolt (H2126--97-2126). To match the restrictor thread.
f) Shuttle valve (H2154--97-2154) Not present on original.
g) Circlip (H2127--97-2127) Not present on original.
BTW I am fitting Progressive springs and Stat-O-Seals (Dowty washers to the Brits) instead of the aluminum washers.
Hope this work may be useful to anyone contemplating a similar conversion.

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#406380 - 11/30/11 8:40 am Re: Converting 1965 T100 Forks to Shuttle Valve Type [Re: Tridentman]  
Joined: Jan 2005
Posts: 1,655
Dick Harris Online content
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Dick Harris  Online Content
BritBike Forum member

Joined: Jan 2005
Posts: 1,655
East Bethany New York
My 66-T-100SR has the changes that you quote,along with a 7" TLS front brake. Works the nuts. Dick

#406401 - 11/30/11 1:52 pm Re: Converting 1965 T100 Forks to Shuttle Valve Type [Re: Tridentman]  
Joined: Feb 2008
Posts: 4,050
Tridentman Online content
BritBike Forum member
Tridentman  Online Content

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Joined: Feb 2008
Posts: 4,050
New Jersey USA
Hi Dick---great to know that it works a treat. I also have a 7" TLS front brake to go in.
BTW---what did you do about the length of the front wheel spindle?
I havent checked it out yet but I understand that the earlier yokes are 6 1/2" centers whereas the later ones taking the TLS brake are 6 3/4" centers meaning that the later spindle (for the TLS) is longer than the original.
Would be grateful to tap into your experience on this.
Many thanks.

#406474 - 11/30/11 9:53 pm Re: Converting 1965 T100 Forks to Shuttle Valve Type [Re: Tridentman]  
Joined: Jan 2005
Posts: 1,655
Dick Harris Online content
BritBike Forum member
Dick Harris  Online Content
BritBike Forum member

Joined: Jan 2005
Posts: 1,655
East Bethany New York
Hi Tridentman,you can use the axel from your earlier wheel as a replacement. Dick

#406490 - 11/30/11 11:17 pm Re: Converting 1965 T100 Forks to Shuttle Valve Type [Re: Tridentman]  
Joined: Feb 2008
Posts: 4,050
Tridentman Online content
BritBike Forum member
Tridentman  Online Content

BritBike Forum member

Joined: Feb 2008
Posts: 4,050
New Jersey USA
Thanks ,Dick,much appreciated

#406499 - 12/01/11 12:29 am Re: Converting 1965 T100 Forks to Shuttle Valve Type [Re: Tridentman]  
Joined: Oct 2007
Posts: 1,272
Wilfred Offline
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Wilfred  Offline
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Joined: Oct 2007
Posts: 1,272
Nanaimo, B.C. Canada
It's good to work with some BSA/Triumph stuff. I'm putting 70 spec forks in 66 triples on my ISDT T100 ( using a 68 Daytona bike ) and because the 66 wheel was quite rough, fitted the T100 axle into a nicer 62 B40 wheel with the 66 T100 brake plate and shoes which happily are the same shoes as the rear brake....don't want a TLS off road. Some day I'll find a better wheel but using two 18 inch wheels with the same tubes and brakes makes sense if troubles occur in the toolies. Hope to get it done for a couple of enduros next year. Cheers, Wilf


"It's about the ride..."
#406519 - 12/01/11 2:08 am Re: Converting 1965 T100 Forks to Shuttle Valve Type [Re: Tridentman]  
Joined: Feb 2008
Posts: 4,050
Tridentman Online content
BritBike Forum member
Tridentman  Online Content

BritBike Forum member

Joined: Feb 2008
Posts: 4,050
New Jersey USA
Hi Overandout----and Triumph tried damper rods for a year and then used shuttle valves until production of the T100 ended in 1974.
The T100 with the shuttle valve is supposed to be the dogs bo**ocks in terms of fork action.
Dicks comments above seem to support that-------

#406556 - 12/01/11 10:10 am Re: Converting 1965 T100 Forks to Shuttle Valve Type [Re: Tridentman]  
Joined: Oct 2004
Posts: 4,429
Tiger Offline
BritBike Forum member
Tiger  Offline
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Joined: Oct 2004
Posts: 4,429
Melbourne Australia
I avoid riding late[er] model bikes but find the shuttle valve fork superior to anything else.

Considering the high unsprung weight of my 8" TLS in relation to modest sprung weight of the bike the fork is brilliant.

Uninvited I will tell a story of 1968 through at least 1985 Jap fork sliders, particularly relevant to the Z1 + series Kawasaki when raced.

Fork sliders were cast of beer can alloy and brake force ex the calipers would both temporarily and permanently deform the slider so that the fork would bind under brakes.

Bloody rubbish design and materials, I cannot recall stripping any Z1/Z1000 fork that returned freely without springs from full travel, some needed a weight fixed by a chain to a fork cap nut [used as a slide hammer] to disengage.

Back in the day you could buy [ex Ross Hannan] for $AU450 a special Kayaba "silouhette" fork, indistinguishable from std apart from a slightly sharper casting edge below the seal holder area.

US Superbike rules demanded such but most thought that extended to carbs and such never thinking that the fork on their road bike may have needed replacement.

Ross Hannan's Kayabas were probably not made of beercan alloy hence worth the money if you had it to spend.

Bloody Jap deathtraps and now I have 40 + yo front suspension which with new springs and oil saves me from my foolishness time and again.






Last edited by Tiger; 12/01/11 10:32 am.

1969 TR6R
7.62 x 51 is not a maths puzzle.
#406595 - 12/01/11 4:28 pm Re: Converting 1965 T100 Forks to Shuttle Valve Type [Re: Tridentman]  
Joined: Aug 2007
Posts: 160
Paul744 Offline
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Paul744  Offline
BritBike Forum member

Joined: Aug 2007
Posts: 160
England
TM,
I did the same thing with my '65 T100. The difference is like night and day, it's like going from a pogo stick to proper suspension. It was such an improvement in ride quality that my regular passenger noticed it before we'd gone 100 yards down the road. For modifications, I'd rate it 3rd (1st = 7" TLS front brake, 2nd = swing arm spindle supports at the ends).
HTH

#406611 - 12/01/11 6:17 pm Re: Converting 1965 T100 Forks to Shuttle Valve Type [Re: Tridentman]  
Joined: Feb 2008
Posts: 4,050
Tridentman Online content
BritBike Forum member
Tridentman  Online Content

BritBike Forum member

Joined: Feb 2008
Posts: 4,050
New Jersey USA
Thanks Paul---gives me extra encouragement that I am on the right track!


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