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k1100rs fork seal replacement. one inner fork wont come out.

 
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1993k1100rs



Joined: 30 Aug 2013
Posts: 24

PostPosted: Sat Sep 26, 2015 4:33 pm    Post subject: k1100rs fork seal replacement. one inner fork wont come out. Reply with quote

As the title says. facing the bike the right inner fork wont come out. what to do? it slides to a point but wont release all the way.

Apparently the bushing is seized. I dont want to use a torch due to burning the black off the outside tube.
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1993k1100rs



Joined: 30 Aug 2013
Posts: 24

PostPosted: Sun Sep 27, 2015 1:30 pm    Post subject: Reply with quote

I have tried heating the outer tube to the point that spit sizzles. I left over night with wd4o penetrating fluid and then heating. I dont want to put map gas on it as it is the tube is painted black. I dont have any vise system so I cant clamp it down and use a wood block and hammer on the outer tube. Not sure what to do at this point. does anyone know what the dealership uses to break these free?
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Scott_Anderson
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Joined: 05 Sep 2006
Posts: 3067
Location: Central Iowa, USA

PostPosted: Sun Sep 27, 2015 4:33 pm    Post subject: Reply with quote

Ok, what all do you have removed from the lower(outer half).



Is the fork still in the bike? It may be easier to remove the lower by force, if the upper stanchion is still clamped in the triple tree.
If you can get the top dust cap off, then get the snap ring (#2) out.
The snap ring should be the only thing really holding the bushings back.
If you can get that out of the way, then just yank it for all your worth.
You will obviously need to replace the bushings and the seal, but they must have needed it anyway......
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1993k1100rs



Joined: 30 Aug 2013
Posts: 24

PostPosted: Mon Sep 28, 2015 7:16 am    Post subject: Reply with quote

scott,
Thanks for your reply. The fork is off the bike. the only thing left is the inner and outer tube. The bike was taken to a local shop with a decent rep. I went to check on the bike as it had been there 3 days longer than originally scheduled. they said they had bad news, the bushing was seized. They effectively gave me the fork to take apart myself. They said they could remove but would not be liable for damage.
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John Clauss
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Joined: 04 Apr 2003
Posts: 693
Location: Robesonia, PA

PostPosted: Mon Sep 28, 2015 10:01 am    Post subject: Reply with quote

Stupid question, you did remove the holding bolt at the bottom of the stantion correct? It is an allen and if it is filled with crud then it may appear to not be a bolt.

I just did this job last weekend and the forks really flew apart once the bolt was removed.
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1993k1100rs



Joined: 30 Aug 2013
Posts: 24

PostPosted: Mon Sep 28, 2015 10:41 am    Post subject: Reply with quote

John Clauss wrote:
Stupid question, you did remove the holding bolt at the bottom of the stantion correct? It is an allen and if it is filled with crud then it may appear to not be a bolt.

I just did this job last weekend and the forks really flew apart once the bolt was removed.


John,
Yes as I mentioned the shop has completely dissembled the fork tube. I can look clear through the tube from one end out the other.
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pegasus
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Joined: 03 Apr 2003
Posts: 196
Location: Ipswich Australia

PostPosted: Mon Sep 28, 2015 8:01 pm    Post subject: Re: k1100rs fork seal replacement. one inner fork wont come Reply with quote

1993k1100rs wrote:
As the title says. facing the bike the right inner fork wont come out. what to do? it slides to a point but wont release all the way.

Apparently the bushing is seized. I don't want to use a torch due to burning the black off the outside tube.



Heat has nothing to do with it. You need to insert a long, thin rod into bottom of the fork through the cartridge bolt hole to compress the fork slider bush. It is not uncommon for these to jam. I had to grind down the tip of a long screwdriver to get mine out. I suggest you take the fork to a bike suspension specialist.[img]http://www.ascycles.com/Illustrated_catalog2/MicroList.aspx?id=51713&catID=&catname=&bindName=Stanchion&bindCat=31_0334[/img]
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LimeyMike



Joined: 15 Nov 2014
Posts: 7
Location: Dakotas

PostPosted: Wed Oct 28, 2015 9:59 pm    Post subject: Reply with quote

Usually the lower bush is twisted and jams the fork. Plan 'B' is to buy a new/used fork. Here is what the pros do. Careful, he drops the F bomb often!

https://www.youtube.com/watch?v=R92FrOQ77wE
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