Wrong fork bushings installed at factory - heavy wear ensues

[pattonme]

I'd say 1/4" and about 1.5" up from the bottom. Measure how deep the "damper rod seal" is and put the hole higher than that.

[pineappleunderthesea]

So to help me understand here, if you have a hole in the fork, you typically have a smaller gap, and if you don't have a hole in the fork, a wider gap is acceptable for lubrication purposes? Or is the large gap unacceptable in all cases?

[markstertt]

Thanks Matt on hole specs, from no comment on bushing, I'm assuming you still believe the small gap bushing is the right bushing?
 
pineapple...I'm guessing what you said is more or less the accepted theory on this topic, however, I don't believe I've heard that any one with the 'right' small gap bushings have drilled lubrication holes but unless otherwise desuaded I think I shall.

[pattonme]

I've installed the "small gap" bushing on all the builds I've done. And neither have I drilled any holes in tubes. And I've done something like 30 sets of forks like that I think. I don't know of any reports of blown or weeping seals or anything else that would indicate there's a problem. If you want to drill the holes, it's not going to hurt anything. Just be sure to properly deburr.

[markstertt]

Thanks Matt, my lower bushings were similar to ones you pictured with slight wear each side of gap, since I had purchased the small gap bushings I went ahead and installed them and just for grins drilled the bleed hole, easy to do and I wanted to make sure the upper bushing had a chance at some lube...Mark

[c0al67]

2015 fz 07, mine were worn at 2,700 miles when I installed the traxxion kit today. Replaced them. Thanks for the heads up on this !

[ssdawood]

I am a little lost. I just bought a 2016 fz07.
 
How does this affect me.
 
How do I go fixing this for myself.
 
Also another question. Patton me is upgrading forks etc. I would be interested.
 
Newb here that's why the questions.

[sorkyah]

I am a little lost. I just bought a 2016 fz07. 
How does this affect me.
 
How do I go fixing this for myself.
 
Also another question. Patton me is upgrading forks etc. I would be interested.
 
Newb here that's why the questions.

The first couple posts in this thread should answer your first two questions
 
@pattonme has a thread here
 
http://fz07.org/thread/1909/fully-adjustable-cartridge-retrofit-forks
that will detail his fork upgrade and just a pm will get you started
 
Good luck
 
 

[gregjet]

I am a little lost. I just bought a 2016 fz07. 
How does this affect me.
 
How do I go fixing this for myself.
 
Also another question. Patton me is upgrading forks etc. I would be interested.
 
Newb here that's why the questions.

They may eventually fix the problem but we all doubt it. A few of us have bought it to Yamaha's attention and they always say " never seen that problem before". Yamaha are liars...full stop ( Don't get me started on their information re the Aussie MT07/mt07HO) 

[Guest ChicagoAJ]

I am a little lost. I just bought a 2016 fz07. 
How does this affect me.
 
How do I go fixing this for myself.
 
Also another question. Patton me is upgrading forks etc. I would be interested.
 
Newb here that's why the questions.

The first couple posts in this thread should answer your first two questions 
@pattonme has a thread here
 
http://fz07.org/thread/1909/fully-adjustable-cartridge-retrofit-forks
that will detail his fork upgrade and just a pm will get you started
 
Good luck
 

The first posts would help if the pictures worked...  
@pattonme - was this an issue on the 2016 FZ07s you worked on?

[sorkyah]

The first couple posts in this thread should answer your first two questions 
@pattonme has a thread here
 
http://fz07.org/thread/1909/fully-adjustable-cartridge-retrofit-forks
that will detail his fork upgrade and just a pm will get you started
 
Good luck
 

The first posts would help if the pictures worked...  
@pattonme - was this an issue on the 2016 FZ07s you worked on?

 
well... thats weird...
 
Couldve sworn i just saw em up
 
My apologies @ssdawood for misleading you

[pattonme]

The pictures in this thread work for me. If your employer blocks DropBox then yeah, they won't show.
 
The bushing persists on every FZ07 that has come to me.

[Guest ChicagoAJ]

The pictures in this thread work for me. If your employer blocks DropBox then yeah, they won't show. 
The bushing persists on every FZ07 that has come to me.

I guess you're right. I'm only on the forum when I'm at work, they work on my home network.  
So what do you charge for your cartridge and this bushing fix?

[twotone]

I am a little lost. I just bought a 2016 fz07. 
How does this affect me.
 
How do I go fixing this for myself.
 
Also another question. Patton me is upgrading forks etc. I would be interested.
 
Newb here that's why the questions.

They may eventually fix the problem but we all doubt it. A few of us have bought it to Yamaha's attention and they always say " never seen that problem before". Yamaha are liars...full stop ( Don't get me started on their information re the Aussie MT07/mt07HO)

 
Hi Greg
If you look up the thread there's a interesting explanation of the 07 bushings, short story: gap is for oil/air passage
Bushings without gap will have hole in staunchions
The likely premature wear, I would think is poor quality manufacturing as is notable with the damper rods.

[Guest ChicagoAJ]

They may eventually fix the problem but we all doubt it. A few of us have bought it to Yamaha's attention and they always say " never seen that problem before". Yamaha are liars...full stop ( Don't get me started on their information re the Aussie MT07/mt07HO)

Hi Greg If you look up the thread there's a interesting explanation of the 07 bushings, short story: gap is for oil/air passage
Bushings without gap will have hole in staunchions
The likely premature wear, I would think is poor quality manufacturing as is notable with the damper rods.

That doesn't explain why they're wearing out in under 5,000 miles. 

[twotone]

Yes it does ?

[Guest ChicagoAJ]

Yes it does ?

So it would be normal to have to tear apart the forks and replace these every 3,000-5,000 miles?

[twf]

Yes it does ?

So it would be normal to have to tear apart the forks and replace these every 3,000-5,000 miles?

No it would not but gap itself is not reason. 

[Guest ChicagoAJ]

So it would be normal to have to tear apart the forks and replace these every 3,000-5,000 miles?

No it would not but gap itself is not reason. 

It is if it's letting out too much fluid to keep a protective coating between the bushing and fork tube (because the gap is too big).

[twf]

How exactly would gap let fluid out when it is submerged in fluid all the time?

[Guest ChicagoAJ]

How exactly would gap let fluid out when it is submerged in fluid all the time?

No idea. Not a suspension expert. Seems to me after reading the thread that the only thing different from the wrong/right parts is the giant gap. 

[twf]

Or maybe it is coating.
Difference between wrong/right part is they are totally different parts and not comparable.
Maybe another totally different part with gap would be just fine.
I have seen thousands of them, some wear and some don't regardless of the gap size.

[pattonme]

the issue is the 'wrong' part is undersized and when stretched to fit the tube (which also yields a large gap) it is no longer round which results in the rapid wear. Take the 'correct' part and slice the gap wider, and you still won't have a wear problem. Zoran and I disagree on the efficacy and necessity of the gap given that there seems to be plenty of slop in the fit between upper and lower legs such that the comparative lack of a gap with the 'correct' bushing configuration doesn't alter flow rates in a negative way.

[twf]

We disagree on many things
I measured few forks and did not find bushings out of the round. Measured brand new tube and used one.
Even cut open outer tube to see inside for wear.
 
 

[twf]

Black painted mark on tube is where gap is. This is brand new bushing, never been inside the fork.