I think I would work over the pits with a small fine file, just to knock off any raised edges. A little light sanding afterwards with some very fine paper probably wouldn't hurt either.
For gaiters, many of us use the ones made for truck shocks. They're cheap and last pretty much forever. They're a bit too long but after shortening, fit perfectly .....
I use the Daystar brand. The larger bottoms are a perfect fit on the 650 lowers. I added hose clamps for looks mostly, they're just snugged up. They're not needed to actually hold the boot on. The smaller tops are a perfect fit on the fork tubes. No clamps or tie wraps are needed, just the friction fit they have is enough .....
So, now the question arises, how does one shorten the boot without losing the nice fitting top or bottom? Well, you'll notice the boots are tapered, the top bellow smaller and each below it gradually getting larger. That allows you to do this - cut the nice fitting top along with one bellow off like so .....
Now hold the remaining bottom portion up to your assembled fork and determine how many bellows need to be cut off. Usually it's 4 or 5. Then simply insert that top w/ one bellow into the top bellow on your freshly shortened lower section. Due to the tapered construction, that small top bellow will fit inside the larger one on the lower piece perfectly. No glue or anything is required, the friction fit between the 2 parts is good enough .....
And like I said, these things are cheap, $10 or less a pair here in the States anyway. I've had the ones on my 650 for about 12 years now and they show no signs of wear (splitting or cracking). I have another bike they've been on for probably 20 years, still look fine.
For gaiters, many of us use the ones made for truck shocks. They're cheap and last pretty much forever. They're a bit too long but after shortening, fit perfectly .....
I use the Daystar brand. The larger bottoms are a perfect fit on the 650 lowers. I added hose clamps for looks mostly, they're just snugged up. They're not needed to actually hold the boot on. The smaller tops are a perfect fit on the fork tubes. No clamps or tie wraps are needed, just the friction fit they have is enough .....
So, now the question arises, how does one shorten the boot without losing the nice fitting top or bottom? Well, you'll notice the boots are tapered, the top bellow smaller and each below it gradually getting larger. That allows you to do this - cut the nice fitting top along with one bellow off like so .....
Now hold the remaining bottom portion up to your assembled fork and determine how many bellows need to be cut off. Usually it's 4 or 5. Then simply insert that top w/ one bellow into the top bellow on your freshly shortened lower section. Due to the tapered construction, that small top bellow will fit inside the larger one on the lower piece perfectly. No glue or anything is required, the friction fit between the 2 parts is good enough .....
And like I said, these things are cheap, $10 or less a pair here in the States anyway. I've had the ones on my 650 for about 12 years now and they show no signs of wear (splitting or cracking). I have another bike they've been on for probably 20 years, still look fine.
