Fork leg help needed

[tmikeyb]

I've been working on building a fork for my 1972 model XS2. I'd like some help with my latest issue. I finally got 1 leg completely assembled. I thought that the 2nd leg was ready to assemble. But, when I went to slide the upper (inner) tube into the lower aluminum leg, It stuck about 4 or 5 inches from the bottom. When I got it out, I found that the inside of the lower outer tube was skinned up pretty badly inside, down toward the bottom. I'm assuming that this may have been caused by the 6 inch extended fork tubes that I removed. All I could think to do was to hone the inside of the lower tube casting until I got enough clearance for it to slide. I tried a flap type hone with light emery cloth in it, then I tried a brake cylinder hone. I used both repeatedly, but neither cut enough to fix the problem. I was using light motor oil as a lubricant. Was that keeping them from cutting enough? Should I use something else as a lube?, or maybe none at all? I can tap the upper tube to the bottom, with a brass hammer, but it's really tight, and difficult to get back out. This whole thing has been a real challenge, but I think that this is the last hurdle.

 

[5twins]

It's possible someone clamped that lower fork leg in a vice and deformed it (made it oval). It's pretty easy to ruin a fork leg like that.

 

[Jim]

Have a look at the outside of the lower... down where it sticks... see if there's any marks from being in a vise?
They're cast aluminum, they'll take an oval shape much easier than most people realize. If that happens, it's a boat anchor.
Put up some pics?

 

[Mailman]

Have a look at the outside of the lower... down where it sticks... see if there's any marks from being in a vise?
They're cast aluminum, they'll take an oval shape much easier than most people realize. If that happens, it's a boat anchor.
Put up some pics?

Yup, what Jim said. I had a very similar problem with my XS2. A prior owner had apparently clamped the lower legs in a vise to change the fork seals, it bent the legs enough that the tubes would no longer slide together. Story and photos here,
https://www.xs650.com/threads/mailman’s-xs2-a-full-on-restoration.51520/page-73#post-572813

 

[tmikeyb]

Yup, what Jim said. I had a very similar problem with my XS2. A prior owner had apparently clamped the lower legs in a vise to change the fork seals, it bent the legs enough that the tubes would no longer slide together. Story and photos here,
https://www.xs650.com/threads/mailman’s-xs2-a-full-on-restoration.51520/page-73#post-572813

Thanks guys. I did think about the possibility that somebody may have deformed the lower leg in a vise. There aren't any marks that would indicate that, but it still may have happened. I don't have a good way to measure the I.D. down that far inside to check. I do have an extra lower leg that the upper fits into OK. I wasn't going to use it, only because somebody broke out a small chunk at the top, probably while removing the seal. The broken out piece is about 5/16 to 3/8 wide. I don't realy see any reason why it could'nt be used, I just thought that I had a better one. I imagine that many of these have broken out pieces at the top. What are your opinions about using that one?

 

[Jim]

I imagine that many of these have broken out pieces at the top. What are your opinions about using that one?

Pics?

 

[Mailman]

What are your opinions about using that one?

It would probably be ok, it’s hidden under the rubber cap. As long as the area that the seal fits into is alright.

 

[tmikeyb]

It would probably be ok, it’s hidden under the rubber cap. As long as the area that the seal fits into is alright.

Yes, that's what I thought. Thanks