Fork it! (Upper fork bushing)

[CamSIXFIDDY]

[size=1em]Hey peepz[/size]

[size=1em]Im replacing the oil, seals and bushings in the forks of my '02 1000, i have done seal replacements and rebuilds [/size]more times than I ever should have had too (wheelies can get expensive) with all my bikes over the years without many issues [shadow=red,left]UNTILL NOW![/shadow]

[size=1em]when putting the forks back together and driving the seals home, the outter/upper fork guide bushing[/size] is not going into its recess in the fork lower properly, which obviously stops me from setting the seal properly and installing the retaining clip. :wall  Everything seems straight and square it just will not fit. The bushing was even put in the freezer the help with installation.

[size=1em]The bushes were ordered from brook suspention (NOX brand), far as im aware the parts are correct and are the new spec bushes that supersede yamahas original spec. [/size]

[size=1em]Lower/Inner/slide BUSHING[/size]
[size=1em]Thickness 1.00mm [/size]
[size=1em]Outer diameter 43.70mm[/size]
[size=1em]Inner diameter 41.70mm[/size]
[size=1em]Hight 20.00m[/size]

[size=1em]Upper/Outter/guide BUSHING[/size]
[size=1em]Thickness 2.00mm[/size]
[size=1em]Outter diameter 43.00mm[/size]
[size=1em]Inner diameter 47.00mm[/size]
[size=1em]Height 12.00mm[/size]

[size=1em]Anyone had an issue with these sizes or brand. [/size]

[Mark YPVS]

Just had the same issue on my Gen 1 , i used Allballs fork kit and couldn't get the top bush to seat all the way same as you, so i ordered gen yam stuff , then a set of forks came up on ebay cheap so i brought them , just changed the oil.


once the bike is together i may attempt redoing the ordinal forks or just sell the lot (forks in bits, gen yam seals & top & bottom bushes)


i have also rebuilt many sets of forks over the years but i did admit defeat on these !! :lol :lol


Mark

[Gaz66]

Had same issue yesdi.
K-Tech bushes are tight as fook, had to file 0.25mm from bush gap to get enough tolerance to get em in.

[b1k3rdude]

Well as Gnasher would presumably say, thats what you get for not getting genuine.

[Gaz66]

Yes agreed.
But you'd expect better from a suspension specialist like K-Tech.


I'll try genuine next time if I live long enough to wear these foccers out  :lol

[b1k3rdude]

But you'd expect better from a suspension specialist like K-Tech.

Yes indeed, you should feed that back to them.

[Trebus]

Had a similar experience with the K-Tech bushes. Did manage in the end but bloody tight! Was reserving judgement as by eye they looked almost identical to the orignals.

Anyway, they went in and forks work as well as a standard dampened set of FZS100 forks can do!

[Dodsy]

I ordered bushes from a seller on eBay far too think apparently there was a huge batch wrongly made they were replaced with the thinner correct ones try xanado  eight on eBay they sorted me out