Fork Seal Teflon Bush Problems

[moulder75]

I am changing the fork seal on my spring (Front Brake) fork on my 08 250 2T. I have done this job a number of times and have made up the necessary tools using odd bits of pipe etc to make it easier.

When re-fitting the brass/teflon bush which effectively joins the inner and outer parts of the forks I have encountered a problem.

Basically the bush is not a tight fit in the outer fork leg and the inner and outer fork legs seperate very easily when I raise the inner part of the fork upwards. This is all off the bike on a bench etc. I have also noticed that there is a ledge on the outer fork leg that the bush sits on which has a chamfer on it. I am not sure if I have made this chamfer by using too much force to insert the bush into the fork leg, or if it was there all along. I hope this is true as I expect a new outer fork leg would be expensive. When I re-fitted the bush ready for a new fork seal I noticed that it was sat in the correction position etc, suggesting that the bush was sitting on its designated ledge within the fork leg. Therefore the chamfer could be a standard part of the fork leg.

I was hoping if it was possible for the bush to have worn making it a loose fit in the outer fork leg.

Any thoughts or ideas gratefully appreciated.

Tony

[kfbmr1]

i just did my seals today on my 02 270, it was my first time but i did notice the bush on the spring side was alot tighter than the damper side, so much so that before it sat flush with the seal bed that it actuall made the inner part go a bit stiff then it freed up as it settled. how much fork oil did you put in???? is it 300ml per leg??? and is it 7w?? cheers