Front fork lower legs - grrrr

[mentalboy]

Anyone got any experience/know a man who can refurb lower legs?

ZZR1100D2, 1994

Replaced the bushes in the forks last year as I had noticed a bit of movement between legs and stanchions. This reduced the play considerably but I was still left with some play.
Fast forward a year and the play has increased again.

I'm thinking that the ally lowers have stretched and become sloppy, sounds a bit suss but the stanchions look good, bushes didn't quite do the trick last time and with 250kg of lump behind regular hard braking it may not be as silly as it sounds.

So the question is does anyone know of anybody who can refurb lowers, I haven't got the foggiest how anybody would go about it but i do know that if anything can be done it won't be me doing it!

I am trawling net for a second set of lowers but these machines seem to have done a bit of a disappearing act recently so any help greatly appreciated.

EDIT: Helps looking for bits if I drop the D2 bit, doh. Looks like I'll find a second pair easy
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Make mine a Corona.

[ricklincs45]

If you don't do any good with 2nd hand bits, might be worth replacing the lower leg bushes, then checking to see if there's any free play when the stanchions are refitted. If there is, it may be that the stanchions are fractionally worn, allowing them to move slightly, even when new bushes are fitted.

Having the stanchions hard-chromed would bring them back to their original size and hopefully get rid of any free play. Fairly sure there are people in the monthly mags' that advertise hard-chroming services.
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Author '80 Bikes, and counting...' Currently getting frustrated with an MZ 125 TS.

[mentalboy]

New bushes make no difference, I think that the lower bush which is on the bottom of the stanchion may have worn the inside of the leg (which is only alloy).
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Make mine a Corona.

[Bezzer]

If it is the lower bush bearing surface worn unless you can get an oversize bush made then you're really looking at another set of lowers. Can't think of anyone I've heard of that refurbs them, it would be a pig of a job and to do it would no doubt cost more than replacement if anyone did do it.
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I used to be indecisive but now I'm not quite so sure.

[mentalboy]