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Ironhead Sportster Motorcycle Talk (1957-1985) For all those that wanna talk about Ironhead Sportster Motorcycles

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  #1  
Old 14th October 2021
Staffords Staffords is offline
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Default 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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Originally Posted by Staffords View Post
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.
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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Old 14th October 2021
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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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Old 15th October 2021
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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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Old 16th October 2021
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Quote:
Originally Posted by Tim The Grim View Post
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
Thanks Tim!
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Old 17th October 2021
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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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