1977 XS650D Build (Restore/mod)

Upon further inspection I’m noticing a small burr/lip on the inside surface. Might try using a scraper to knock it down. Sigh. Hope it works out.
 

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I then used a depth gauge to measure the distance from the top of the headtube to the inside lip, where the race sits up against. There is about 0.8mm of a difference from opposing sides.
Try putting a square on the outside of the tube and make sure the top lip of the tube is square to the side. Make sense?
 
Try putting a square on the outside of the tube and make sure the top lip of the tube is square to the side. Make sense?
Yes. The only issue is that when the race goes in, it has a tendency to “rock” back and forth with enough force to it. It’s not sitting flush. I’m hoping this lip on the inside is the culprit.
 
Thinking out loud Not sure here .
Does it matter .. The load goes through the bearing balls Or ?? and some thread there to adjust play
If there is space enough
The only way to keep it from knocking back and forth is to tighten it with too much force. It ended up making the front end feel squirrelly as it’s fighting against the tight bearings to return to center.
 
That will most likely ruin the heat treatment (hardness) of the race.
:banghead: I didn’t think of that. Sigh. I really don’t want to strip the frame and send it off to a machine shop but I think thats what I might need to do. Unless I can figure out another option… any ideas?
 
any ideas?
Yeah, let's find out if it's actually broke...

Seat the top race as if it's going back together.
Scrub that race and the bearing with solvent so it's squeaky clean... no signs of grease.
Paint some prussian blue (black or blue sharpie also works in a pinch) all over the outer race. Any tool maker/layout dye will work actually.
Reassemble (just the triple) like it's ready to ride and move it back and forth 'tween the stops for a good 30 sec to a minute.
Disassemble and give us a good pic of the marks made in the prussian blue. I want to see if the rings it makes are even or not. That'll tell us if the race is cocked or not.

We'll figure it out from there....
 
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