Topic: fork rebuild question

[gflenn]

First, thanks for all the information on this site.  I've learned a lot in the last couple weeks. 

I just got an 82 cb650 nighthawk (my first bike) and am pretty much going through everything.  I started to replace the fork seals and the left slider has a groove maybe .010"-.015" deep and a little wider most of the way down the inside.   It looks like I can get a new one but they're not exactly cheap.  Another route would be to try to find a used fork somewhere but I'm not sure about what other years/models are exact replacement.  Condition of all the other components seems good.  It had ATF in it and the upper seal washer was missing so I think they have been rebuilt before.

Do you think rebuilding with the groove will cause any major issues?  Is it just a bad idea?  I hate to put things back toghether when they're not right, but if there's no issue I'll get over it.  I'll buy new if necessary.

Gary

[bryanj]

Not sure what you mean, If the groove is in the chromed steel leg it needs replacing or it will pee out oil;
If the groove is on the outside of the alloy slider no problem,;
If its on the inside of the slider where the seal goes you can try filling in the groove with silicone and you have a 50/50 chance of it working

[gflenn]

Thanks for the reply. 

The groove is on the inside (important) surface of the alloy slider and is in line with the whole fork assembly .  It looks like something broke or got stuck in the lower bushing at some point in time and wore in the groove.  It is below the fork seal. 

The only problem I can think of is that the damping would be slightly affected since oil could bypass the normal valving or maybe force it up to and out of the seal.  I'm just not sure.

Gary

Edit:  Think of a scored cyclinder from a broken ring.

[bryanj]

If thats is the only place it is and not in the "hole" where the seal fits i would reassemble  with no internals fitted and make sure the alloy slider moves freely on the steel leg, If so personally I would reassemble with new seal and try it. One groove is a very small percentage of the "bearing" surface and it ought to be OK. If it really worries you you may get a new old stock slider , or even complete leg from Dave Silver, only if you fit one new complete leg  you ought to fit a pair, similarly with used--try and get both from the same bike so all the bits are of a consitent age/wear

[gflenn]

Thanks very much, bryanj.  I'll put it all back together and maybe keep eye out for a spares.  It didn't seem too bad but I wanted a second opinion.  I'm new to riding so I don't know some of the subtle causes of handling problems. 

It's a good point about matching components.  I hadn't thought about that.

Thanks again.

Gary