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Fork Seal foibles

  • Thread starter Thread starter FiftyGS1100G
  • Start date Start date
F

FiftyGS1100G

Guest
Well sure could use some advice on this, I'm doing the fork seals on my 82 GS1100G and the disassembly went well but I'm having a whale of a time getting the seals out. I'm using BikeCliffs method of pressurizing the forks to roughly 200 psi trying to get them to pop. The dust covers are off, the wire ring and its been sitting for 24 hours with no movement. I've tried loosening the 8mm allen head bolt in the bottom of the forks but all it does is spin and spin and not loosen. On BikeCliffs website there's another method by Matchless that calls for a 19mm bolt to be welded to a 2' long piece of re-bar with a T top to hold the nut from spinning but I don't have a welder to do that with. Any idea's ? greatly appreciated. Cheers Paul
 
You can just push a broom handle down the tube instead of the threaded rod / nut set up. Push hard and it will hold 99.9% of the time, even on real tough ones.
 
Hey Paul!

Long time, no see. :)

You can also use a long ratchet extension, or maybe two or three, and on the end place a spark plug socket backwards. The outside hex (19mm?) should be the same size as the socket on the bottom of the damper assembly.

paulkardolus_050510_04.jpg



Thank you for your indulgence,

BassCliff
 
FiftyGS1100G said:
On BikeCliffs website there's another method by Matchless that calls for a 19mm bolt to be welded to a 2' long piece of re-bar with a T top to hold the nut from spinning but I don't have a welder to do that with. Any idea's ?
Click to expand...
I don't have a welder, either, so I used a 2' section of 1/2" all-thread and four nuts. Works just as well.

IMG_2027.jpg


IMG_2032.jpg


.
 
There is an earlier thread discussing fork tools. I have a pic of the one I built on that thread. See if you can find it.
 
The upside down spark plug socket with all the 3/8th extensions I own did the job on my 78 1000 forks.
 
Okay here the the tool I made for my forks, a length of 1/4 inch hot rolled steel rod, weld a T at the top of the tool and a 19mm nut at the bottom, simple, strong and it works.

carp pic didn't post...
 
Last edited:
Okay here is the thread where a pic of my fork tool is, GS Motorcycle Discussion Area #26
 
And, I have seen using a drill/driver to insert 2 drywall screws and pry them out. Use a drill bit to make pilot holes first.
-Bookmon
 
Hi,

mrbill5491 said:
Dry wall screws? Gotta see the pics.
Click to expand...

Just run the screws into the seal. Use the screws to pull out the seal. Be careful not to scratch the fork tubes.

I've also heard of people using heat (bottle torch) to partially melt the seals and then dig them out.


Thank you for your indulgence,

BassCliff
 
Aaaah to take the seals out...guess I missed something in the post, Thanks. Oh I just use this huge craftsman screw driver I have, works, they pop right out.
 
They Popped!

They Popped!

Well just as BikeCliff said " a little patience goes a long way" well a paraphrase anyhow. I left the tubes sitting while I went off to work my shifts and "voila" both seals did pop out of their seats. Yaaay! New seals in, tubes reassambled and bike is on its way to another trouble free riding season. Thanks for everyone's "opine" on the subject! Cheeers Paul:lol:
 
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