Fork seals stuck

[Dodo]

I cant get the old fork seals out of my suzuki goose forks (they are a non-cartridge USD fork, the same as a rg125f)

I have removed;

- dust seal and circlip.
- top cap, drained the oil, and removed spring.
- bolt at the bottom of the fork leg.

I have been trying to slide the lowers out from the uppers, using the momentum from the slide to try and hammer out the old seals.

The old seal wont budge and I am worried about causing damage.

I haven't replaced the seals on this type of fork before, have I missed something straight forward? Has anyone got any tips for removing stuck fork seals?

[hayd3n]

use plenty of heat (heat gun, boiling water etc) , i had to mount mine into a solid vise and really pull and tug , got them out in the end :)

[spanner spinner]

use plenty of heat (heat gun, boiling water etc) , i had to mount mine into a solid vise and really pull and tug , got them out in the end :)

what he said, use a heat gun to heat the outer tube around the seal area and they will come out easy. The tube needs to be to hot to touch to soften the seal and break the seized area, BUT wait for them to cool down before fitting the new seals.

[Dodo]

Thanks for the help guys, tried using boiling water today with no luck. Will borrow a small propane torch and have a go at heating them up soon.

[spanner spinner]

Thanks for the help guys, tried using boiling water today with no luck. Will borrow a small propane torch and have a go at heating them up soon.

NO!!! do not use a flame as this will damage the finish on the fork leg, go to the warehouse or supercheap and buy a heat gun see links below. They are handy for many other things around the house to, good tool to have.

http://www.supercheapauto.co.nz/online-store/products/2000W-Heat-Gun.aspx?pid=135300#Cross

http://www.thewarehouse.co.nz/red/catalog/product/Samson-Heat-Gun-2000W?SKU=1382477

[jellywrestler]

use plenty of heat (heat gun, boiling water etc)


what he said, use a heat gun to heat the outer tube around the seal area and they will come out easy. The tube needs to be to hot to touch to soften the seal and break the seized area,


Thanks for the help guys, tried using boiling water today with no luck. Will borrow a small propane torch and have a go at heating them up soon.


NO!!! do not use a flame as this will damage the finish on the fork leg, go to the warehouse or supercheap and buy a heat gun see links below.

while you're there get some of those cheap reading glasses as it appears you need some.........

[Dodo]

Ok, will give the heat gun a go. Have seen videos of people using small gas torches to heat them up with success (e.g. http://www.youtube.com/watch?v=eru0iV8sU8Y ) but can see why it is best to avoid this. Cheers for the help spanner spinner, will have to swing by the warehouse for the heat gun (will pass on the glasses).

[actungbaby]

Ok, will give the heat gun a go. Have seen videos of people using small gas torches to heat them up with success (e.g. http://www.youtube.com/watch?v=eru0iV8sU8Y ) but can see why it is best to avoid this. Cheers for the help spanner spinner, will have to swing by the warehouse for the heat gun (will pass on the glasses).

I watched a you tube video guy cut his old seal and ground the broken end smooth and

Used that to push the new seals in place . i got to replace seal on one fork leg too

If you going hold the things in a vice make sure use piece wood each side to protect them.

I got my heat gun from tool shed real chaep 40.00 bucks good for fixing ps3 ,s too

[Premature Accelerato]

Watched a guy in a bike shop pull a fork leg out once. He put the lower section in a vice (non USD) and gave the upper tube an almighty yank. Got the tube out and sheared the top of the fork leg off complete with seal. Veeeery funny.

[Robert Taylor]

Watched a guy in a bike shop pull a fork leg out once. He put the lower section in a vice (non USD) and gave the upper tube an almighty yank. Got the tube out and sheared the top of the fork leg off complete with seal. Veeeery funny.

And you cannot put brains where they are not supposed to be. Many forks have fixed bushings right under the fork seal with a smaller diameter moving bush on the internal slider.

If you slide hammer forks apart cold its WAY TOO BRUTAL. Often the sliding bush will ride slightly into the fixed bushing, paring away teflon lining and creating a furry edge. Not good and highly unproffessional. ALWAYS use a heat gun for removal and also refitting. The area needs to be heated not only where the seal immediately is but also where the bush is underneath it. It needs to be heated so that its uncomfortably hot to touch, so the heat gun ( and NOT a flame ) needs to be applied to it for some time due to the heat soak inherent in alloy tubes.

Heating for fitting makes it surprisingly easy to push the seal in ( which should also be greased on its outer diameter ) and largely eliminates the risk of seal distortion if you are using less than ideal ''Kiwibiker / No 8 wire '' tools advised by 5 minute internet keyboard ''experts''.

[jamesfry]

most convential forks have a bolt on the bottom that you unscrew and you can simply pop the seals out by snapping it apart.

[benhall]

most convential forks have a bolt on the bottom that you unscrew and you can simply pop the seals out by snapping it apart.

no.... the bolt holds the damper rod in... go away