cannot split fork leg

Bertie · Post by **Bertie** » Mon Oct 24, 2011 12:48 pm

ive got both fork legs off for a fresh lick of paint, new seals, new oil and some hagon springs. one leg has all come apart beautifully, but the other leg just will not seperate. i have everything off, down to getting the oil seal out and pulling the leg apart, but it just wont go. had a heat gun on it, clamped it in a vice and pulled very hard repeatedly, ive tried soaking it in lubricant and it just will not budge. the seal is only about 2mm from the edge but just will not come out

any suggestions on how to get it apart?

(1990 nc29 btw if it makes a difference)

amorti · Post by **amorti** » Mon Oct 24, 2011 1:57 pm

Bertie wrote:ive got both fork legs off for a fresh lick of paint, new seals, new oil and some hagon springs. one leg has all come apart beautifully, but the other leg just will not seperate. i have everything off, down to getting the oil seal out and pulling the leg apart, but it just wont go. had a heat gun on it, clamped it in a vice and pulled very hard repeatedly, ive tried soaking it in lubricant and it just will not budge. the seal is only about 2mm from the edge but just will not come out

any suggestions on how to get it apart?

(1990 nc29 btw if it makes a difference)

The damper bolt in the bottom of the fork leg is the only thing which holds the leg together. Once that is out, there is only the fact that the bushes won't go out past the fork seal, so only friction of the seal is then holding the leg together. Clamp the leg in a vice by the brake lugs (you are painting them anyway) and really REALLY give it some welly, using the leg as a slide hammer to remove the seal. It will come out, just keep at it.

If it really won't come out (I've never come across one that my 11 stone bulk couldn't heave out, but apparently they do exist) then you can apply heat using a blow torch, which apparently will help you ease it out. I would leave it for a last resort, though.

Were you going to replace the bushes anyway? I recommend it now, as they may well have become damaged by your efforts. Only cheap, but can make a big difference to handling if yours are worn (increased stiction, and play in the forks), and of course if you need to do them then it will need new seals and oil which you are currently doing anyway.

Bertie · Post by **Bertie** » Mon Oct 24, 2011 2:07 pm

ive had it clamped in a vice, a heat gun applied and a 16 stone friend give it some shit but it still wont go. every time you pull it the leg gets stuck and requires a mallet to free the leg so it can slide back down, which i dont think is a good sign. bushes probably are worn after the amount of effort put in. i was wondering if there is some way to destroy the seal without causing damage to the metalwork, some form of acid that might break down the rubber possibly?

amorti · Post by **amorti** » Mon Oct 24, 2011 2:44 pm

Douse it in plus-gas or another similar penetrating oil? Wouldn't fancy acid as it might potentially eat at the seal seat.

Avoid the temptation to dig in there with anything sharp, it'll end in tears when you scratch the chrome.

Bertie · Post by **Bertie** » Mon Oct 24, 2011 2:56 pm

plus gas is a good shout, might pop out to pick some up. im being particularly careful with anything sharp, im not overly keen on ripping the chrome off!

Bertie · Post by **Bertie** » Tue Oct 25, 2011 2:23 pm

it really doesnt want to move at all. i have spent hours trying to pull it apart with no luck. anyone got any other suggestions? ive heard about filling it full of oil and compressing it to press the seal out but without a hydraulic press i dont think ill be able to get anywhere with that!

Bertie · Post by **Bertie** » Thu Oct 27, 2011 1:13 pm

i had to give in and give it to the bike shop. sounds like they're going to destroy it with a drill or something!

Post by **GF Racing** » Thu Oct 27, 2011 1:27 pm

Very common problem this - we sacrifice the fork lower - carefully grinding at the mud guard mount clip point. Lowers are cheap enough - good tubes are not.

Cheers

amorti · Post by **amorti** » Thu Oct 27, 2011 1:40 pm

GF Racing wrote:Very common problem this - we sacrifice the fork lower - carefully grinding at the mud guard mount clip point. Lowers are cheap enough - good tubes are not.

Cheers

I guess if you are going this far then maybe it's a good time to upgrade to VFR lowers?

Bertie · Post by **Bertie** » Thu Oct 27, 2011 4:30 pm

the bike mechanic said it was the worst he had seen in his 30 years working on bikes!

all apart now, lower bush looks a bit rough so might have to invest. £10 seems a lot of money for a copper ring though

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