Replacing Front Fork Slider Bushings

The front fork slider bushings (25, Fig. 2F-3) may be replaced using three special tools.

1. Part No. 96255-50, Fork Slider Bushing Puller.

2. Part No. 96285-50, Bushing Driver and Guide.

3. Part No. 96300-50, Bushing Reamer and Pilots.

REMOVING SLIDER BUSHINGS. Position fork slider in vise as shown in Fig. 2F-6.

Remove spring ring, steel retaining washer and felt wiper from slider upper end. Pry out oil seal with large screwdriver.

Install Fork Slider Bushing Puller, Part No. 9625550, so the three claws expand inside the tube under the upper, or shorter bushing. Place puller cap in oil seal counterbore, apply oil to screw threads and steel washer. Turn nut down against puller cap and use engine sprocket wrench on nut to extract bushing. See Fig. 2F-6.

Remove lower bushing in the same manner.

INSTALLING FORK SLIDER BUSHINGS. New, replacement bushings are installed with Fork Slider Bushing Driver and Guide, Part No. 96285-50.

Wash out fork slider and lubricate slider bore with engine oil. Position new lower bushing in bushing driver guide to compress bushing, then place driver guide with bushing in slider oil seal counterbore as shown in Fig. 2F-7.

Drive bushing through the driver guide into fork slider. Bushing is positioned correctly in slider bore when second groove from top on driver is flush with top edge of driver guide. Do not drive bushing deeper than specified, or it will collapse enough so it cannot be finish-reamed.

Install upper bushing in the same manner lower bushing was installed. Drive it into slider until lower groove on driver is flush with top of driver guide. This positions upper bushing 1/16 in below slider oil seal counterbore.

REAMING BUSHINGS. The Fork Slider Bushing Reamer with pilots, Part No. 96300-50, is used to ream the bushings to finished size.

Attach long pilot to reamer as shown in Fig. 2F-8 The long pilot fits into the unfinished lower bushing, acting as a guide, while reaming the upper bushing. Do not drop reamer into bushing. Slowly lower reamer into cutting position and ream bushing, turning reamer clockwise. Continue turning reamer clockwise as it is being extracted when cut is finished.

Remove long pilot from reamer and attach short pilot. Finish lower bushing in same manner as upper bushing. Use caution when passing reamer cutters through the upper bushing.

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