fork bushings dilemma

I recently had a set of 1978 kz1000 fork lowers powder coated. despite my CLEAR INSTRUCTIONS they did not mask off top of the fork tube. I'm pretty pissed about this because I literally wrote "NO" where i wanted them to mask. They only masked for powder not the sand blasting. It doesn't seem like the sand blasting got into the tube too far, but it did peel a bunch of Teflon off the bushing at the top of the tube where the inner tube rubs. There is now quite a bit of play between the fork inner and outer at this location. This coated bushing is not shown in the parts diagram, nor is it mentioned in the service manual. It looks like Racetech has a bushing that has the correct dimensions that may work (36x12x2) I have another pair of forks that I could use but the caliper mounts have been machined on these for my caliper conversion; something I would rather not do again.

how do I get this bushing out? there is very little lip on the backside, probably less than .5mm. Also its in there pretty deep, my seal puller won't reach it.

You need a inner bearing puller, 80 Euro this set.

lemato.nl/product/hbm-17-delige-binnenlager-trekkerset-11-58mm/

Hmm, thats a bit more than id like to spend on something I will use once, but good to know thats a possibility

It is a solutions to your problem. Take your fork lowers and bring them to machine a shop with this tool equipped and let them pull out the rings for a little tip.
I would do so if i wouldn`t have the puller tool :whistle: :whistle: :whistle:

Hey Doc, How about just a right sized flap wheel in a 1/4" air grinder. Then just hone it?
powder coat is hard enough to work as a bushing, might tighten it up a little too?

You should be able to borrow the bearing puller from autozone/advance auto, if not for free then for a minimal cost.

Been curious about lower leg bushings for a long time. We'll be watching this with interest.

Recently updated the steering neck bearings on our '93 CB750 Nighthawks to tapered bearings. There's no way to get under the lower (inner) stem race with any kind of puller. We very carefully used a small cutoff wheel to slice the race very close to the surface of the stem. That relaxed the race enough to allow it to be dislodged easily by tapping a chisel into the shallow gap between the race and the lower triple tree where it meets the stem.

Perhaps something similar would work here? Two ideas:

1) Use a fine-tooth, straight, plunge blade on one of those vibrating tools to cut the bushing's metal ring vertically along the wall of the leg. Need not even have to completely sever the metal ring the teflon is built on. Just deep enough to relax the pressure, so that a thin blade could be inserted between the bushing and leg, very close to the cut, and gently prying/twisting the cut edge away from the bore in the leg. That should relieve the pressure that's the bushing into the bore it's pressed into enough that it could be removed with needle nose pliers.

Or,

2) There is a dremel bit that is a tiny globe, about the size of a BB. Use that to accomplish the same cut. Might be easier to control than a vibrating plunge blade.

We'll be interested to see this play out, and how close to the original dimensions the new bushings are to the originals.


Good Ridin'
slmjim & Z1BEBE

Doc, an autoparts store that lends out tools might have a 'blind hole puller' as they are frequently used on the pilot bearing in the flywheel of manual trans cars and trucks. Those are far smaller in diameter, but if the tool comes in a kits as shown above, you may have a solution.

Bummer. I wish I had some advice for ya.

Some 550's also have undocumented bushings on the fork tubes and I've been trying find a source to get those replaced or re-babbitted. If you go that route please post who you used.

Through some fugly butchery I was able to extract the bushing. I first turned a 37mm washer that was 1/4" thick. Drilled and tapped that and flatted two edges so it could be passed though and reoriented to catch the bushing. it pulled out easy. The small bolt is to keep the washer from spinning. just waiting on new bushings and the forks can go back together. best part is it cost me nothing but and hour of my time

Well done, necessity makes inventive. :woohoo: :woohoo: :woohoo:
Mission accomplished!!!

Love it:laugh: