Topic: Rebuilding Forks Tomorrow

[Madmax01]

I'm attacking my 74 CB550 forks tomorrow with a rebuild.  I've got new fork seals, 10wt fork oil, and every thread/video made on the process.  You guys got any last minute tips for me to help make this a 1 day job?
Thanks a bunch!

[the technological J]

boil the seals in hot water if they dont come out .. i have heard about people  using a blow torch to mealt the old seals loose.. dunno if its good advice  or not but what ever you do dont scratch the outter OD

[allhonda]

Hopefully the forks are not "pitted". I they are pitted you can fill in with jb weld and sand smooth to the finish. I have done this successfully on Trail 90 projects I have worked on. This would become more than a 1 day project though.

[faux fiddy]

Did you find the thread on this site- I think it included  you tube video. Thread was called something like   "Is changing fork seals really this easy?"

It's within the last year, perhaps around January.

[ekpent]

If they are the same as a 750 don't forget a broom handle.

[RickB]

Yep, a broom handle will server you well tomorrow if, like on my 400, you can't get the allen head bolts out.

[Johnie]

I have better luck with that allen bolt by cracking that loose before I do anything. I suppose you could drain the oil out first, but I have never had to use the broom handle. Just crack it loose right at the start. Don't have to take it out...just crack it loose. Maybe you will be lucky too. 

[SohRon]

Did you pick up new piston rings for the lower pipes as well? Mine were pretty serverely worn, and replacing them made a real difference. Also, when re-installing, don't forget the special spacer washers that go in the gaps on the top TT clamps.

[ekpent]

Johnie has a good point on cracking those at least loose first. I have had to put the lowers in a soft jaw vise to hold them well to crack loose off the bike.

[Madmax01]

Thanks for the input guys.  Unfortunately, I had already removed my tubes before breaking the allen bolts.  Those bolts are on really good.  My buddy is bringing over his allen socket set.  Hopefully that plus a vise will do then trick. 

What do you guys think of the pitting on the upper park of one of my forks.  It looks like its from rust in the triple tree area.  Is this OK?  Lastly, one of my forks (the one without the rust) had nasty brown goo around the upper seal and the oil was a white/grey color.  What's this about?  Did water get in past the seal?  I've got new seals, so hopefully this will get fixed.

Thanks for all the help!

[Duke McDukiedook]

Could be water, I would recommend changing the springs while you are changing everything else. Odds are your springs are tired.

[Madmax01]

I got both forks rebuilt.  Turns out the fork with the white fluid had a bad seal at the top of the upper fork. Water got in the fork.  I didn't order those seals so I couldn't get her rolling today.  I did finish up each fork and store them off to the side until I get the new seals.  I can already tell this is going to make a huge difference.  The sliding motion is much smoother now.  I'll check in to new springs since I don't have it all buttoned up yet.

One quick tip I discovered to help install the lower fork seals.  I didn't have the correct sized PVC pipe, so I improvised with a roll of electrical tape.  After rolling off 18" or so I had the perfect size to tap the seal in to place.I also didn't have to worry about hurting the seal since the tape had some give to it.  Pretty cool if you ask me.  :-)

Thanks for the help everyone.

Max 

[Madmax01]

Anyone know if you can buy fork cap o-rings without the actual cap?  Any chance I can use a generic rubber o-ring to replace my torn ring?  I'd hate the pay $60 for a new set of caps.

[tomkimberly]

Your Honda dealer should still be able to get them, P/N 94608-50000 (23 X 2.8mm).

Tom

[cobrajunkie]

Anyone know if you can buy fork cap o-rings without the actual cap?  Any chance I can use a generic rubber o-ring to replace my torn ring?  I'd hate the pay $60 for a new set of caps.

I found o-rings at the local hardware store.   They weren't EXACTLY the same size but real close and seam to work fine.  I found o-rings that were larger (thicker) and some a bit thinner than OEM size.  The thicker rings didn't fit well and would have torn if I force fit them.  The slightly thinner ones worked fine.