Posted updated checklist [V7]
Progress today
Touched up black paint on front and rear rims – mostly scratches near edges. Some historical, and some from damage I did with tire spoons.
Reassembled right fork leg with new seals and oil. Found new stainless 8mm x 30 bolt was a bit too long to seat, leaked. Reused original (good) brass bolt and it sealed well.
The custom 41mm seal driving tool worked well. Pounded on a wood block from the top to seat both the upper bush and oil seals.
Bought a new stainless 8mm x 25 bolt for the left leg. Completed reassembly of left fork with new seals.
Reinstalled both forks on the bike. Reinstalled both clip-ons.
Installed front wheel. Found the new stainless left fork bolt protruded very slightly into axle space – its head longer than the original Showa bolt’s. Next time we’ll buy OEMs. Filed it down and polished surfaces and axle to fit.
Reminder: Will need torque wrench to verify all fasteners installed today are correctly tightened.
Wirewheeled and polished heads of the 4 rear wheel lug nuts.
before and after