K11 Owners Group

Jnclem · Posted: Fri Sep 23, 2016 6:43 pm Post subject: Really Screwed Up My KLT

I went to replace my leaking fork seals today on my '93 K1100LT. The job went very well, until I installed the right lower. As I was sliding it on, it got bound up somehow. It would not go up all the way, nor would it rotate without quite a bit of pressure. I took it off twice, but couldn't find anything out of place. Finally I put the axle in it and slowly worked it up farther - big mistake.

I tried to take it off again, but it seems to be hung up on the lower guide bushing or something. I managed to remove the clip, the new (now ruined) seal, the ring that sits under the seal, and the upper guide bushing with the slider still on the bike. I hoped that would allow me to get it past the lower bushing or whatever it's caught on. No way. It is stuck so hard that I am thinking I'm going to have to cut it off with a grinder and find a new lower.

I tried heating it with a heat gun, but have not used a torch yet. I doubt I can get enough expansion to get it off, but it's the last thing I can think of before I take a cut off wheel to it. I have no idea what got so stuck in there.

Any ideas on how to get this thing off?
_________________
'93 K1100LT, '89 R100GS

Scott_Anderson · Posted: Fri Sep 23, 2016 9:49 pm Post subject:

Well, don't take a cutting wheel to it, or you will be replacing it for sure.
You may have to remove the entire fork assy out of the bike to be able to attain the force needed to separate the lower from the upper.

Sounds like you will need a new seal, the spacer ring, and both sets of bushings.

If it really won't come apart, you may as well just buy a replacement fork and not waste your time cutting it apart--just to throw it away anyway.
_________________
Ride safe.

1995 K1100LT 0302044
2017 FLHTK Ultra Limited
Garmin StreetPilot 2820
Garmin Zumo 550
Garmin Zumo XT
"One who does not ask questions is ashamed to learn" Danish proverb
1997 K1100LT 0302488(R.I.P.)
1997 R1100RT ZC62149(sold)

Jnclem · Posted: Fri Sep 23, 2016 10:41 pm Post subject:

Jnclem · Posted: Sat Sep 24, 2016 2:10 pm Post subject:

Never mind! Got it! Heating the slider allowed me to get it off. Lower bushing was pushed out of place and jammed. All else seems fine, so I'm ordering a second set of seals, and upper and lower bushings.
_________________
'93 K1100LT, '89 R100GS