Hello.I own a 1970 A50 . I replaced all 4 fork bushings as well as the plastic sliders. My forks stick in the compressed position. Apparently, the bushings are too tight. I'm not sure if I should polish the OD of the lower bushings or hone the ID of the uppers. Also, could the plastic sleeves be a problem. This front end was a fossil when I started, so I don't have the old parts to go by. Are the fork tubes supposed to be a close fit in the upper bushings, or a few thousands clearance? Any feedback would be appreciated.
When rebuilding old forks you should wash all the sludge out of the lowers and then inspect the inner surface. Most likely you will find some rust and pitting that has formed over the years. I take a brake cylinder hone and wet the stones and inner lowers with kerosene and then lightly hone them till the rust is gone. Rinse and repeat as needed. You dont want to remove too much metal, only the rust. Once you've done this you will find that your lower fork bushing should not bind in the bore anymore. Hope this helps!