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I've gone through the original HD manual for that bike and asked Dr. Google several ways several times, but can't find a definitive answer to the specs for tube to bushing clearance on a 1976 FLH. I do see where they say if the seals leak the bushings are likely worn out. Or if you have a knocking noise and a seal leaking or no dampening, it's likely the bushings worn out. But I can not find a numeric value. Anyone have an answer to that?
The bushings have some wear, but I can still see hone marks from when they were fitted previously. The seals weren't leaking and the fork oil looked great when I disassembled it, but this is a bike that has been sitting for at least 10 years, so I'm not sure that's a reliable gauge to decide on. Cleaned up of any oil and inserted the tubes in the sliders, I can feel a slight side movement.
Also, if the bushings are worn out, is it worth upgrading to the late 1977 up front suspension? Or are there other better options that allow me to maintain the original sliders etc. Worth noting, I do not have the bushing removal and installation tools. I can size them, but still need a spec to do that correctly.
I believe a fit of .0025 - .0030 would be design for bushing of this type.
However if you have less that .006 I would think you are good to go.
If it did not leak with an old seal then a new seal would do even better.
Thanks for the response. I don't have a bore gauge small enough to measure the bushings, so I'm using a telescoping gauge and then measuring with a micrometer. I measured multiple times to minimize the chance of errors and came up with the same measurements. The left side has .002 and the right just under .003. Hopefully it will perform and function as it should, and the seals will hold up. They are the original US made (not Showa) slider and trees for the bike, so I'd prefer to use them.
Paul, I know a year old, but you evaluated .003 clearance of chrome tube to slider bushing?? That's awesome, I would love to have that, now I'm looking at my 63 panhead slider bushing wear, I got .030! That's right 30 thousands a side, total .060!
chrome tube measure 1.620 , bushing in lower slider measures 1.650 one way, 1.680 at 180 degress!! NO one sells the tools to remove bushings , especially lower one, I can cut upper out, but it's unbelievable, not 1 YouTube on how to remove and install these!
Mike
On mine, the bushings looked fairly good with some wear but I could still see some hone marks, but the tubes were rusted and not usable for me.. So the biggest problem I had was finding tubes sized correctly, which was more difficult than I expected. Most were undersized by about .006 which meant I would have to rebush the lowers to get the fit I wanted. The tubes should be 1 5/8 or 1.625.
If your tubes are in good condition, you will need to rebush the lowers. I only know of two shops that may be able to do those. I emphasize may because I did not have to have mine done. But I'd check with @johnjzjz on this forum who has a shop in New Jersey and is very knowledgable and capable. Not sure he does these bushings, but I'f check with him as I'd trust him.
Over the years the tubes have been in the same box two different sizes - so what we have done for a decade is bush the legs and size fit the tubes as left and right to size - its the only way to get it correct
I had the problem John described from two vendors. The only vendors I'd buy non OEM tubes from are Custom Cycle Engineering or Forking by Frank. I've used both and they have been sized spot on.
I made a tool and pulled upper bushing out, worn bad, I'm replacing and using same tubes, they're straight and not to worn, still chrome, definitely time and thar bushing worn through some of the hard chrome coating, but new bushing, and if I get clearance without honing, beautiful, it'll be way better than the .060 oblong wear, geez .010 total true interference I'd be happy, new felt seal ready to go! Here's my tool and a pick of worn bushing
Zoom in , you can see the worn to one area almost wearing thru!!
Be sure to not press the new bushing in too far. The bushings are usually reamed ot honed using a sunned home to ensure they are correctly aligned. Hopefully yours will be good to go. But check that the tube sides up and down smoothly.
I'd start with 15w fork oil and see how the rebound feels. Lots of others say they have run 20 or 30w fork oil to get enough dappening and rebound.
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76 FLH Slider to tube clearance
