This bike has how many miles ? Did you remove the tubes from the bottoms ? It's 
easy enough to slide off the syntalic bushings and look at them. If they show 
scuffing or scarring, it's time to replace. No, there is no spec. .007" is a 
ton. Is that at full extension ? That isn't a good check. Half way is. Now I do 
it by feel but I expect that less than .003" is more like it. May ask a polite 
question ? Would you be so kind as to take us step by step through what you 
have done (method) and how ? I've written several times about fork seal 
replacement and I'm starting to wonder how you went about it. I'd just like to 
get on the same page. I had techs in Florida that could do the job without 
removing the tubes from the bike and didn't take off the caps. That's a bizarre 
method but it can be done. (flat rate breeds all manner of things) They'd take 
off the caps to change oil or springs. 

--- On Thu, 12/31/09, oldschoolgwin <[email protected]> wrote:

From: oldschoolgwin <[email protected]>
Subject: [Nighthawk Lovers] Fork seals part 2: slider bushing
To: "Nighthawk Motorcycle Lovers!" <[email protected]>
Date: Thursday, December 31, 2009, 10:20 PM

Fork seals part 2: now that the 6hr fork tube cover bolt saga is over;

Ok - I cleaned every thing up real nice and assembled back togther to
see how it all feels.

Results of the wiggle test: With the slider bushing installed (fork
seal NOT installed) i get precisely 0.007" (.2mm)  movement (as
measured with a dial indicator) of the fork tube inside the slider
bushing when the fork tube collapsed all the way.  It feels like more
than 0.007" but as measured thats all it is.

It felt tight before taking it apart. I specifically checked how it
felt as i didn't want to find a sloppy fork.  I suspect the before/aft
difference is the oil seal / dust seal is not installed and no oil
film in between the slider bushing.

Is this normal or does this mean the slider bushing is worn and needs
replacing (there is not a spec in the OEM manual for slop assembled)?

Thoughts?

Thanks,

Paul

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