Can't Remove Fork Tube from Slider

[slipring]

Help!

I'm in the process of replacing the oil seal on my right fork assembly.  Why?  Last year I accidentally installed it upside down!

I've removed the snap ring and am at the point where I'm "pulling hard on the fork tube using quick in and out strokes" to overcome the "interference fit between the fork slider guide bushing and the fork tube guide bushing".  Unfortunately, the interference fit is not wanting to be overcome.

Any suggestions?  Shall I simply cut the existing, upside down fork seal with an Exacto knife and pull it out in pieces with a needle nose pliers? 

I've yanked on the tube/slider assembly plenty (both in and out of a vise) with no luck.  If I keep trying to break the interference fit, am I going to damage guide bushings or other fork components?

[Laitch]

It is installed like this?


How's the ride?  Good? Leave it and don't tell anybody else. Enjoy being an iconoclast. Maybe the ride wasn't so good and that's why this is up for discussion.
  :dunno

In your case, it isn't removed by "pulling hard using quick in and out strokes." My tendency would be whanging the hell out of the seal using the tube like a berserk slide hammer operator. If you choose that direction, record the process for YouTube and send us the link so we can cheer you on from here.

HO!      HEY!      HO!                     GO!      SLIPRING!        GO!    :yippee:

You're liable to damage something no matter how you try to remove it—one of the main reasons assembly procedures should be double-checked for understanding before being undertaken. Scraping the inside of the tube with sharp objects is to be avoided, or leakage will follow. The seal is a little tougher than meat in a lobster claw. You'll get it out—one way or another though. I'm confident of that.

 :2thumbup:

I'm sure more help is on the way. johnny probably has a technique for this he's rolling up for presentation. Clear your lungs and get ready to take a deeeeep breath.

[slipring]

Yes.

[johnny]

greetings...

its this motobrickers opinion that the bushings should be replaced at the same time as the seals because it tightens it all up in there and less likely to wear new seals...

i have had to replace many seals before i started replacing the bushings... now the motos with new bushings never gotts seals again... i do run traxxion dynamics and do use a homemade sealmate and change my suspension fluid with honda ss8 10wt at the beginning and again in the middle of the riding season... all that helps...

j o

[Scott_]

Is it leaking......no, leave it be and ride it like you stole it.......   :2thumbup:

if yes then, as Laitch has suggested keep plugging away at it. 

Either
1. the seal will come out with the fork tube bushing,(btdt, my came out this way) or
2. the slider bushing will come off of the slider and stay in the fork tube as the slider comes out.......

I think that in either case you will need a new seal an 2 new sets of guide bushings..........

[duckhawk]

almost boiling water on the outer tube, loc-tite cold freezie stuff on the inner tube. Don't spill the hot water on the inner tube.

[slipring]

Hey all.  Thanks for quick replies.

Laitch and Scott_,  The ONLY reason I'm opening her back up is that the oil seal is leaking.  I replaced both fork tube oil seals last year and after a ride or two noticed the right fork leaking oil whilst the left was fine.  I finished out the year that way, but need to straighten it out.  Last year the fork tubes and sliders separated just like Clymers Manual describes. 

Johnny, Last year I did replace both oils seals AND both sets of guide bushings AND both dust seals. 

duckhawk, While reviewing problem with co-worker this morning, he also suggested heating the fork slider! 


I think I'll mount the fork slider (outer tube) in the bench vise and in a position where I can really lean on it.  If that doesn't work, I'll heat the fork slider up with hot, hot water and try it that way.  I'll post results asap.

[Laitch]

The ONLY reason I'm opening her back up is that the oil seal is leaking. 

You only put the seal upside down in ONE fork leg?  This is another example of disregard for the beauty of symmetry. :nono

"Leaning" is unlikely to do much unless you've got body mass, grip strength and gravity in your favor. A video of your process would be instructive for others though.

Usually something fouled up like this would need shock -orce to remove it because it was designed to seal and you're moving it in a direction that makes it seal tighter. Surgical incision along the center of the flat between outer edge of the seal and its stiffening ring for its entire circumference might work. A pick might be inserted intp the kerf then the outer ring pulled upwards and dislodged. Marring metal surfaces should be avoided.

[bizzaro]

Maybe a dumb question but, did you take out the screw at the bottom of the fork? Part # 27. If it is still in there they will not separate.  I only mention this because you didn't.  I just did my forks, and they slid right out. My forks are probably a bit different being the 1100.  Those bushings are very expensive. Especially the upper/outer bush. Almost $100 for just those two.  The lower/ inner bushings where around $70 for the set. You really want to preserve them if ya can.  At 50k my lower/inner bushings were shot. The upper/outer  weren't that bad but I replaced them while I was in there anyway.

[slipring]

Laitch,  "Lean on it" wasn't meant to be literal.  I will be applying force in a manner that will likely approach "shock and awe".

bizzaro,  Hmmm... I think you may have hit the screw on the head.  I assume that I read the Clymer Manual instructions closely, but...


I will report results back to the team late tonight.

[Laitch]

Laitch,  "Lean on it" wasn't meant to be literal.  I will be applying force in a manner that will likely approach "shock and awe".

I think practice operating in the literal might help you with instructions in the future. :giggles

Nice catch, Bizz, in this house of mirrors!

[slipring]

And the winner is... (drum roll, please)... bizarro!

Of course it was the bolt at end of the fork slider (part no. 27)!  Upon re-reading my Clymers Manual (and after correctly doing this process last year) I'm embarrassed at my mistake!  With bolt out, a few quick pulls on fork tube/slider and the fork tube popped right out.

The good news is that she'll be back up and running by tomorrow night or Wednesday night at the latest!

Thanks for the assist(s).

[Laitch]

Second prize winner—drum roll, please—goes to slipring Scott, for his new definition of correctly. :clap:

[The Mighty Gryphon]

 :2thumbup: :clap:


It is unbelievably comforting to know that I'm not the only one making dumb mistakes and overlooking obvious stuff. 

[bizzaro]

Glad you got it sorted out and will be on the road again shortly. :2thumbup: I always check the obvious first..........unless I forget?  :giggles