Front fork disassembly

G-Man · Post by **G-Man** » Wed Nov 18, 2015 12:52 am

Husker

I may have some spares at home but I am away until the weekend. I will check for you when I get back.

G

Husker45 wrote:After disassembly and inspection on the fork pistons they are below minimum spec for outer diameter plus had what I would best describe as flats wore on one of them. Based on my review of the parts diagram these pistons should have a part number of 51442-268-040. When I called Nick at Ohio Cycle the fork pistons he had under that part number had grooves instead of knock pin holes for attaching to the fork pipe.

Next I tried western hills Honda. Same thing. The fork piston under part number 51442-268-040 had grooves and no holes for knock pins. And because I am persistent same result with College Bike Store and Floyd's.

So I'm stuck. I want to replace these fork Pistons but either because I have the wrong part number or because they no longer exist under that number I can't find replacements.

Any thoughts or ideas greatly appreciated. Thanks.

Husker

Husker45 · Post by **Husker45** » Wed Nov 18, 2015 7:05 am

Thanks G-man. Would happily reimburse you for their value and shipping. Enjoy your week.

Husker

G-Man · Post by **G-Man** » Fri Nov 20, 2015 5:02 am

Husker

I have these. PM me, if you are interested, and we can sort out something.....

Pretty sure these are part #51442-268-010. 51442-268-040 was the later type.

If yours have flats you might want to check teh inside of your fork sliders where the fender bolts go in. Sometime people use over-long bolts and distort the tube. This puts the flat on the bush when the tubes are pulled out with force.

G

Husker45 wrote:Thanks G-man. Would happily reimburse you for their value and shipping. Enjoy your week.

Husker

Husker45 · Post by **Husker45** » Fri Nov 20, 2015 10:17 am

G-Man

Sent PM (I think - new to the whole PM thing). Let me know if you don't get one.

Husker

Husker45 · Post by **Husker45** » Sat Feb 13, 2016 3:10 pm

As I continue my trail and error on these pinned front fork Pistons it appears they are not interchangeable. From what I can tell the fork piston was assembled to the fork tube then the holes were drilled and pinned with subtle differences in the spacing from fork tube to fork tube. In fact you have to rotate the fork piston until you find the right orientation for the three holes to match up. Can anyone confirm this was how Honda manufactured these (note, serial number of frame is CB77-62-22734)?

If this is indeed the case replacement fork Pistons would have to be undrilled blanks and then matched to the fork tubes. That would seem to be near impossible at least with my machining skills. Thoughts appreciated.

P.S. G-man this would indicate I could not use your used fork Pistons.

G-Man · Post by **G-Man** » Sat Feb 13, 2016 4:08 pm

Husker

I don't see why you couldn't drill a second set of holes, if necessary.

G

dave_c · Post by **dave_c** » Wed Mar 23, 2016 8:31 am

Hi all, I'm a little late to this party but I wanted to show you what I ended up with as a very effective set of tools for pushing these pins out. From way back I had a seal puller and an old school automotive drum brake adjusting tool. Combining these as shown allowed a very controlled application of force to the back of the pin. Without the brake tool (or similar) backing up the seal puller, the fulcrum was in the wrong place and I broke the hardened tip of the puller.

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