FHG

Well I am finally done round 1. The Montesa is back together and running. I tore it down to the frame, painted and rebuilt it. New rear shocks, tires, seat and 1 new lower fork. It took me 1.5 weeks to get the forks off and now I can rebuild the front end in 30 minutes. Fun and a lot of learning. I still need HELP! Front forks are rebuilt but I have parts missing. 1 fork was seized - it was missing the lower fork piston bushing. I had to get one machined and then honed down to fit. It works amazing now BUT this fork is 1.5" shorter than the other. The shock I did not rebuild it missing something in the top half of the fork that stops the piston. Explanation - Front Fork - Top Nut - main spring, piston - So top half of fork when I look down I see a square stopper that stops the fork piston. On the shock i rebuilt when you look in you see a stopper or spacer in the tube. I did not want to try to push this part all the way up the fork tube in case it got stuck. So I assume I rode it this way in the 90s. BUT the forks are not balanced, so when you rebound only one fork would top out and the springs are not equal pressure. Will it damage the fork over time? I found the manual but the parts are not listed anywhere. Thanks Francis

Thanks ALL - I ordered the lower leg on EBay - I can always repair it later if needed. $115 seems safe and it looks like new, just like my current forks. All parts ordered - seat from Spain - can't wait to put it all back togegether.

I broke the bottom of the lower fork on my Montesa rebuild. ChatGPT told me to hammer down....the forks come up.... I should have realized but didn't. I heard about welding but I think here in Alberta, CA it would be very expensive and no warranty or guarantee. I see exact parts on ebay in the US that look almost new. They look too good to be true but I assume I could rebuild the forks with new seals... Or is it best to try to get an entire fork - upper and lower? The old shocks seemed to be functional 25 years later. Any recommendations would be great.

Question - for the rear shock - they are seized down I think. What measurements do I need to get something new? I just want it to work - does not need to be vintage....?

Thank Kev - I will check out the shock idea. I don't need all vintage yet, just want to get it running. I rebuilt the carb and after a few leaks and fails, it started right up after 20-25 years!

GOOD Day -complete rookie here - I am looking for advice, feedback and connections. I touched a 2 stroke for the first time in 30 years and I am hooked. This is my dad's bike, I think he bought it new and raced it and gave it to me in the 90s. My dad passed away last year so I decided to rebuild it. I rebuilt the carb, reused everything and it fired right up. First goal, tires and shocks - get it rideable so a third generation can try it and then I will pull it apart next winter and rebuilt it. Initial questions: - everything is original. Tires are in bad shape, cracked any way to keep them? - Rear Shocks - completely seized - not sure how to size and replace them? - Front shocks - ChatGPT tells me I can rebuild them, they work but rubber is cracked and oil would be 40+ old.