K11 Owners Group

joeangi · Posted: Mon Feb 02, 2009 9:15 am Post subject: Fork Disassembly

Help, I am rebuilding the forks on my '94 K1100RS and I am stuck. I have done fork work before on the K100, so I figured no big deal. I removed both fork legs, and figured I would start on the right one. First off, mud came out when I drained it....Long story short I have the whole fork apart (who used an aluminum pipe as a spacer anyway?) Cleaned the whole thing up, but cannot separate the fork tube from the slider? I have removed the snap ring from the fork seal, but since the fork tube is still in, I cannot remove the seal. I figured that the weight of the tube would act like a slide hammer and drive the seal out, but no.....

So, the fork tube will not go down into the slider (it is as long as the other fork, extended) and I can get it out until I get to the machined area, about another 6". I can actually see a hole in the tube, if this is any reference. I attempted gentle heat to the fork seal area....it just feels stuck, won't go down, and won't come out? Anyone have some words of wisdom?

Thanks, Joe

Rider · Posted: Mon Feb 02, 2009 12:06 pm Post subject: Fork work

Joe,

I have been there before. There is a bolt up in the recess on the bottom of the fork slider. To get it out you need to either buy an impact wrench or take it to a motorcycle shop and have them use their impact wrench. They won't laugh at you much because it happens all the time on other makes of bikes too. I am told that a good electric impact wrench will work if you don't have a compressor.

Sometimes the bolt will come out with a regular wrench but don't count on it.

Good luck.

Ed
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Flying Duck · Posted: Mon Feb 02, 2009 12:17 pm Post subject:

I put the caliper mounts in a bench vice. Then using the factory (6mm?) with a pipe on the end for leverage I can get that bolt out.
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joeangi · Posted: Mon Feb 02, 2009 1:27 pm Post subject:

The bottom bolt is out! I used my impact wrench (learned from my K100 forks) I have all the "guts" out...but the fork tube won't come out...and it won't go in all the way????

pegasus · Posted: Mon Feb 02, 2009 5:19 pm Post subject: Fork dissassembly

The bushes at the bottom of the slider could be jamming. Try inserting a long screwdriver (with the tip ground down) in from the fork staunchion end to push the bushes back in.

joeangi · Posted: Mon Feb 02, 2009 5:40 pm Post subject:

I could try that, but there is not much room as the fork seals are still in place...can't get them out with the fork tube still in the slider.