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14th October 2021
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Know It All
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Join Date: Oct 2014
Posts: 173 Sportster/Buell Model: XLCH Sportster/Buell Year: 1961 Other Motorcycle Model: FXE Other Motorcycle Year: 1976
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33.4mm fork bushings
I bought a set of new repop hard chrome fork tubes for a 71-72 33.4mm front end I'm rebuilding. The right side fork leg went together no problem. The left side seems like the bottom bushing in the fork lower is too tight. The tube get stuck. I've confirmed the tubes are the same size and will swap to either lower with the same result, the left fork lower seems to be the problem. What do you use to ream the bushings in these old 33.4mm front ends? Thank you.
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14th October 2021
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Master Custom Bike Builder
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Join Date: Jun 2005
Posts: 3,416 Sportster/Buell Model: XLCH Sportster/Buell Year: 1969 Sportster/Buell Model #2: XLH Sportster/Buell Year #2: 1960 Other Motorcycle Model: XLCH Other Motorcycle Year: 1959
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Quote:
Originally Posted by Staffords
I bought a set of new repop hard chrome fork tubes for a 71-72 33.4mm front end I'm rebuilding. The right side fork leg went together no problem. The left side seems like the bottom bushing in the fork lower is too tight. The tube get stuck. I've confirmed the tubes are the same size and will swap to either lower with the same result, the left fork lower seems to be the problem. What do you use to ream the bushings in these old 33.4mm front ends? Thank you.
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harley made a tool for it in the 60's, but the majority of those are long gone or worn out. The machine shop that I use does it on a sunnen hone.
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"Ride 'em, don't hide 'em!"
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14th October 2021
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XL FORUM TEAM MEMBER
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Join Date: May 2010
Location: Pottstown PA.
Posts: 15,386 Sportster/Buell Model: xlch Sportster/Buell Year: 1960 Sportster/Buell Model #2: 883 custom Sportster/Buell Year #2: '03
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Bills custom cycles in Bloomsburg PA offers a bushing service for that.i just saw it again last saturday night on ebay.i can look for it again if you're interested.
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72 1000cc barrels and heads, s&s 41/2'' flywheels, sifton cams, s&s super B w/ zippers thunderjet w/yost powertube, andrews gears,and shafts, competition engineering kevlar wet or dry clutch, 72 oil pump, morris magneto w/auto advance and single fire module, cycle electric generator w/electronic regulator,73 cu.in.
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15th October 2021
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MetalWorkingXLFan
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Join Date: Jun 2011
Location: Far West Texas
Posts: 688 Sportster/Buell Model: XL1200V Sportster/Buell Year: 2013 Sportster/Buell Model #2: KHK Sportster/Buell Year #2: 1954 Other Motorcycle Model: Valkyrie Other Motorcycle Year: 97
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I have a ball hone I could lend you. I rebuilt two sets of lower legs a couple years back and used it to get to finish size. You can squeeze it through the top bushing and just spin open the inside one.
Send me a PM
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'54 KHK (Current Build), '13 XL”72” Hard Candy, '97 Honda Valkyrie. I’m Retired 🥃
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16th October 2021
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Know It All
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Join Date: Oct 2014
Posts: 173 Sportster/Buell Model: XLCH Sportster/Buell Year: 1961 Other Motorcycle Model: FXE Other Motorcycle Year: 1976
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Quote:
Originally Posted by Tim The Grim
I have a ball hone I could lend you. I rebuilt two sets of lower legs a couple years back and used it to get to finish size. You can squeeze it through the top bushing and just spin open the inside one.
Send me a PM
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Thanks Tim!
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17th October 2021
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MetalWorkingXLFan
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Join Date: Jun 2011
Location: Far West Texas
Posts: 688 Sportster/Buell Model: XL1200V Sportster/Buell Year: 2013 Sportster/Buell Model #2: KHK Sportster/Buell Year #2: 1954 Other Motorcycle Model: Valkyrie Other Motorcycle Year: 97
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A link to some pics of doing my lower legs.
My home shop made bushing puller assembly and upper seals.
Note: the ball hone needs an extension epoxied on to reach the inner bushing.
https://postimg.cc/gallery/D0DJJcm
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15th January 2022
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MetalWorkingXLFan
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Join Date: Jun 2011
Location: Far West Texas
Posts: 688 Sportster/Buell Model: XL1200V Sportster/Buell Year: 2013 Sportster/Buell Model #2: KHK Sportster/Buell Year #2: 1954 Other Motorcycle Model: Valkyrie Other Motorcycle Year: 97
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Just a follow up to say that Staffords is a stand up guy,
that I lent him my hone and he used it successfully and returned it in fine shape.

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16th January 2022
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Know It All
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Join Date: Oct 2014
Posts: 173 Sportster/Buell Model: XLCH Sportster/Buell Year: 1961 Other Motorcycle Model: FXE Other Motorcycle Year: 1976
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Quote:
Originally Posted by Tim The Grim
Just a follow up to say that Staffords is a stand up guy,
that I lent him my hone and he used it successfully and returned it in fine shape.

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Thank you Tim for loaning it to me! Greatly appreciated!
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