Rebuilding forks, other important parts?

I'm rebuilding the forks in my '82 KZ750H (they leak oil). Nothing else in the fork tubes looks very worn, and the main springs measure out correctly. So aside from the main seals and dust covers, are there any other parts that are commonly replaced during this job?

Another thing; the upper tubes, where they pass through the seal, are slightly rough. You can't really see this, but you can feel it. Would it be taboo to take some 1500 paper and polish this area?

Thanks!

Hi Polcat,

No there are no other parts that are commonly replaced during a fork rebuild. However the roughness you've found is a killer for new seals. Polishing them up won't hurt but typically these fork tubes are chrome plated. If the rust has gotten under the chrome, they're toast.

KZCSI

There is a website called "Forking By Frank" or at least their was years ago. Found it:http://www.frankmain.qpg.com/

When I reworked mine, I just replaced the seal and dust covers. Oh, I also replaced the rubber seal in the Schrader air valve....helped with loosing air. Just got a kit from a bike shop for that.

Yea, I just plan right now to swap out the seals. My dust covers look new so I'll probably reuse them.

I made my own crossover valve for the air, so I only have to add air to one valve and it fills both tubes. I filled it with about 10psi (carefully checked this), and the next day I had the two puddles of oil all over the garage floor under the forks! What a waste of new oil. That's why I figure the seals are gone (that's where the oil came from.

polkat wrote:

Yea, I just plan right now to swap out the seals. My dust covers look new so I'll probably reuse them.

I made my own crossover valve for the air, so I only have to add air to one valve and it fills both tubes. I filled it with about 10psi (carefully checked this), and the next day I had the two puddles of oil all over the garage floor under the forks! What a waste of new oil. That's why I figure the seals are gone (that's where the oil came from.

are you sure 10 psi is correct?..and if it is, you put it in with a bike pump, not a compressor, right....?

My book says the most common amount is 10psi, in a range of 8 to about 15. Yep, used a tire bicycle tire pump. Took a few tries to get it at 10.