650 Forks, How do I....

[fossie]

Now there is a way , You won't find mentioned in any manual.
Any trained mechanics look away NOW!

Get an old screw driver grind the side of the tip so it's sharp, then cut a bit the side of the tip so it is a hook.
Then wrap a rag around the fork station after draining all the oil out and removing springs , so the part of the stantion in use for suspension is in the fork leg.
Remove the circlip washer front above seal that holds it in .

Now hammer the tool you just made in to the seal, and lever back, repeat the process on the opposite side. Heypresto seal out.
Make sure you flush the forks out with kero or such like , but do that anyway no matter how you change the seals.

To fit new seal lightly oil stantion slide seal down as far as you can, place old seal over it , and tap with a piece of wood until new seal is seated.

Total time 20 mins for both seals.

[G0FHM]

Now, THAT is my style of mechanicking

Good job I bought that grinder the other day... I've only used it to grind 3 bolt heads off so far!

Will modificate a screwdriver tomorrow

[Pop-Kat]

As you've said the forks were full of an oil/water mix don't you think it would be best to strip them properly then check and clean the internals.

[G0FHM]

I know Mal....

I have toyed with the idea..... but think I ought to do it properly!

I'll crack the top open tomorrow and have a look at the length of tool I need... If a job's worth doing and all that!

J

[KeKat]

I use a long length of square steel rod. Grind the end to a square pyramid (this will stop the piston from turning)

place the rod in the vise, then insert the fork leg on the rod and use a impact driver on the bottom bolt holding the piston.

I must have done about 10 sets of forks this way, never had a problem.

[katscott]

I used a piece of 2x1 batten cut down to fit inside the fork leg to hold the piston still. I do usually try to crack the allen bolt off whilst the legs are still in the yolks, seems to be easier. Last strip down I had to use my specialist batten tool.

[G0FHM]

I'm totally lost here guys!

Never done forks before!

I've removed the top hex nut - and had a face full of spring

Looks like I can see a capscrew down the bottom. I take it something else needs to be wedged down the bottom to stop the whole lot turning?.

Looking at the exploded diagram of the forks, it's just confusing! (give me a circuit diagram, or a wiring diagram i'm fine!).

Looks like i'm gonna be subbing this one out!

J

[katscott]

If you turn fork leg upside down you will see an allen head bolt in a recess. you need to undo this to strip forks.

[KeKat]

Here it is

[G0FHM]

Lovely, super, smashing, great! Now I know what to look for, i'll have a pop at it.

Scott's 2x1 tool sounds like a good idea! Will report back tomorrow - it's grandfathers 90th today, so otherwise engaged!

Thanks,

J