Stuck Fork Seals.

[Dozer7380]

So after I decided to rebuild the forks and do the PVC mod , I forgot to account for the extra displacement for the PVC vs. the metal spacer.

The new seal I put in didnt like this . So now I am putting in new seals again and the "old" seals dont want to come out. I think they may have a slightly larger OD ( The "lifetime" seals)

So the question is , whats the best way to get a stuck seal out. I have been slamming the inner tube for the better part of an hour and getting no where.

[Black_peter]

First off you put in the oil without the spacer.. So I don't know why the PVC effected this. I assume you mean the fork seals blew out because of that? Something else was wrong IMO.

Second if you can't get the current seals out using the tube as a "slide hammer" something is really wrong.
You did remember to remove the spring clip right?

[Dozer7380]

I replaced the whole metal spacer with 1 piece of PVC and Im thinking it blew the old seal .

The wave washer is out and the thing is stuck in there really good. i was thinking hair dryer?

[arsenic]

http://fiche.ronayers.com/Index.cfm/Module/Main/TypeID/26/Type/Motorcycle/MakeID/2/Make/Suzuki/YearID/36/Year/1995/ModelID/6407/Model/GSX600F_KATANA/GroupID/265755/Group/FRONT_DAMPER_MODEL_K_L_M_N_P_R_S_T

item 6 is the clip he's talking about, I've heard that called a lot of things, wave washer is not one of them.

[Dozer7380]

Yes the #6 clip is out. Tried boiling water on the seal , Heating the tube . NO go .

[Steveb]

The BOTTOM bolt is out too, right? The allen key at the end of the fork leg, in the centre?

#11 in the fiche?

[Dozer7380]

I dont have that allen bolt. Everything is free except the seal.
Im thinking about drilling two holes on either side of the seal to relieve the pressure.

[Dozer7380]

My memory is getting really bad. After working on the left shock for about 2hrs I gave up. The next day i decided to take a look at the right fork and THER IT WAS> the allen. I then realized there was a sleeve in the left one blocking the allen .

After taking it out , the seals still didnt come out without a good fight.
After getting it all back together I have a leak from the allen in the Left fork.. (ME) please!


Man on top of doubting all the kat gurus, I'm loosing it bad! Thanks for the help fellas .

[LORDMETAL]

how do i get the BOTTOM bolt out of the forks...turn right or left??

[Steveb]

It's a standard RH thread bolt.

[LORDMETAL]

thanks

[LORDMETAL]

ok i got the bottom bolt loose,but it will not come out.the damper rod just keeps turning . is their a tool i need buy?

[LORDMETAL]

i got it,using a piece of thin wood that has been filed to a taper at one end (a thin broom handle will do) push it down into the tube until it pushes against the bottom. Hold it tight & the bolt was out without a problem.:mrgreen:

[TrickyRicky]

Mmm - a broom stick! Now there's an idea LordMetal ! I was just gonna mention the special tool required which is basically a long T-hex. A standard socket won't work (too wide), but using ur broomstick idea, instead of shaping saw a 10mm head, one could drill a 8mm hole and slot a 10mm hex in there (assuming its a 10mm). Cheap and nasty ... but it'll work if u don't want to buy/weld the right tool or just don't have the time.

If the fork seal itself was stuck, this could have been an alternative :

http://www.yamahaclub.com/forums/lofiversion/index.php?t6911.html

[the wind]

After taking it out , the seals still didnt come out without a good fight.
After getting it all back together I have a leak from the allen in the Left fork.

replace the washer,the mannual says to use threadlock.i would use a little teflon tape on the last threads by the head of the bolt.