Specialist mountain bike fork repair
Fork Lower Leg Bushing Replacement
Professional removal, replacement and sizing of worn, loose or damaged mountain bike fork lower-leg bushings.
Professional Fork Bushing Replacement
Fork bushings support the upper tubes inside the lower-leg assembly and help maintain smooth, controlled movement through the fork travel.
Worn, damaged, incorrectly seated or poorly sized bushings can create excessive movement, binding, harshness and premature wear to expensive fork components.
CJSuspension uses specialist workshop tooling to remove the existing bushings, install the correct replacements and size them to the fork’s upper-tube assembly.
Specialist workshop repair
What Is Included
- Initial fork inspection and fault assessment
- Measurement and inspection of bushing movement
- Inspection of the upper tubes and lower-leg assembly
- Removal of the existing lower-leg bushings
- Cleaning and preparation of the bushing bores
- Installation of the correct replacement bushings
- Professional sizing of the bushings to the upper-tube assembly
- Check for smooth movement through the fork travel
- Inspection for binding, excessive clearance or alignment problems
- Final workshop function testing
Fork support and alignment
What Fork Bushings Do
The bushings inside a suspension fork’s lower-leg assembly support and guide the upper tubes as the fork moves through its travel.
The correct clearance allows the fork to move freely while controlling unwanted movement between the upper tubes and lower legs.
If the clearance is too large, the fork can develop noticeable movement and accelerated wear. If the bushings are too tight, incorrectly aligned or incorrectly sized, the fork may bind and feel harsh.
When to book
Signs of Worn or Damaged Fork Bushings
- Noticeable movement between the upper tubes and lower legs
- Knocking or clicking when the front brake is applied
- The fork feels loose under braking or through rough terrain
- Binding or excessive friction through the travel
- The fork feels harsh despite correct setup and servicing
- Uneven or accelerated wear on the upper tubes
- A bushing has moved, tilted or become incorrectly seated
- The fork does not move smoothly after lower-leg installation
- Previous impact damage to the lower-leg assembly
- Excessive contamination or lack of lubrication has damaged the bushing surface
Accurate inspection
Movement Does Not Always Mean the Bushings Are Worn
Some movement at the front of the bike can come from the headset, brake pads, hub bearings, axle interface or other components rather than the fork bushings.
The fork must be inspected carefully before replacement is recommended. Bushing clearance can also feel different depending on lubrication, temperature and fork construction.
CJSuspension checks the fork for the source of the movement and inspects the upper tubes and lower-leg assembly before completing the repair.
Correct running clearance
Why the Bushings Must Be Sized
Installing replacement bushings is only part of the repair. The bushings must provide the correct running clearance for the fork’s upper tubes.
Bushings that are too tight can create binding, poor small-bump sensitivity and excessive friction. Bushings that are too loose can allow unwanted movement and reduce control.
The replacement bushings are sized using specialist tooling and checked against the fork’s upper-tube assembly to achieve smooth movement without excessive clearance.
Important workshop requirement
The Upper Fork Assembly May Be Required
The complete upper fork assembly may be required so the replacement bushings can be sized and checked correctly against the actual upper tubes.
If the fork has been disassembled before arriving, send the crown, steerer and upper-tube assembly with the lower legs unless the workshop confirms otherwise.
The bushing fit cannot always be accurately checked using the lower-leg assembly by itself.
Inspection findings
Upper-Tube and Lower-Leg Damage
Worn or incorrectly positioned bushings can damage the upper-tube coating or create wear lines on the stanchions.
The lower-leg bushing bores can also be damaged by impacts, incorrect installation or a bushing moving out of position.
Bushing replacement cannot repair severely worn upper tubes, cracked lower legs or damaged bushing bores. If additional damage is found, the workshop will contact you with the available repair options before proceeding.
Servicing requirements
Additional Fork Servicing May Be Required
The fork must be disassembled for bushing replacement. Depending on its condition and service history, a lower-leg service or complete internal service may be recommended at the same time.
Fresh lubricants, seals and correct reassembly help prevent contamination or worn service components from affecting the new bushings.
Any additional servicing will be confirmed before the work is completed.
Fork compatibility
Compatible Fork Brands and Models
CJSuspension can replace and size lower-leg bushings in compatible mountain bike suspension forks from brands including Fox, RockShox, Öhlins, Marzocchi and other supported manufacturers.
Replacement bushings, dimensions and workshop procedures vary between fork models and production years. Some forks use non-replaceable bushings or require complete lower-leg replacement.
Contact the workshop with the exact fork model and year before booking if you are unsure whether replacement bushings are available.
Queenstown or nationwide
Drop Off or Send by Courier
You can deliver the fork directly to the CJSuspension Queenstown workshop or send it from anywhere in New Zealand.
Clean off heavy dirt and package the fork securely. Protect the upper tubes, lower legs, axle interface, adjusters and steerer tube from impact during transport.
If the fork has already been disassembled, include both the lower-leg assembly and the complete crown, steerer and upper-tube assembly unless the workshop has confirmed otherwise.
Please complete the online booking form before sending the fork.
Fork bushing information
Frequently Asked Questions
Important information about diagnosis, bushing sizing, additional servicing and damaged fork components.
Does movement in the fork always mean the bushings need replacing?
No. Movement can also come from the headset, hub, axle, brake pads or other components. The fork should be inspected before bushing replacement is confirmed.
Do you need the complete fork?
Usually, yes. The complete crown, steerer and upper-tube assembly may be required so the replacement bushings can be sized and checked correctly against the actual upper tubes.
Is a fork service included with bushing replacement?
Not automatically. The fork must be disassembled for the repair, and additional lower-leg or complete internal servicing may be recommended depending on the fork’s condition and service history.
Will new bushings repair worn stanchions?
No. Replacement bushings cannot restore damaged or heavily worn upper-tube coatings. Stanchion damage must be assessed separately and may require repair or component replacement.
Can the bushings be replaced in every suspension fork?
No. Some forks use non-replaceable bushings, unsupported dimensions or lower-leg assemblies that must be replaced as a complete component. Compatibility depends on the fork model and parts availability.
How much does fork bushing replacement cost?
Pricing depends on the fork brand, model, replacement-bushing availability and any additional servicing or damage. Provide the exact fork details when booking so the workshop can confirm the requirements.
Will I be contacted if more damage is found?
Yes. The workshop will contact you before completing significant additional repairs or replacing higher-cost components.
Can I send my fork from outside Queenstown?
Yes. Forks can be sent to the workshop by courier from anywhere in New Zealand. Complete the booking form first and package the fork securely.
Restore correct fork movement
Book Your Fork Bushing Replacement
Book online, drop the fork at the Queenstown workshop or send it to CJSuspension by courier.