Trouble with fork seal replacement

[Mike]

I got the seals out, but that's as far as I seem to be able to make it. The two write ups on BassCliff's site, and the manual just say to take the fork cap off. My forks don't have a cap like shown in BassCliff's write up, just an air valve and that's it.



I've tried taking the air valve off, but it just turns and I'm absolutely at a loss. Any thoughts?

[hampshirehog]

If you push down on the centre with a socket a bit larger than the air valve you will expose a spring clip. Prise that out with a screwdriver - cover with a cloth so that it doesn't fly off to a never before seen part of your workshop, forever to hide there. I'm still looking.....

[Mike]

If you push down on the centre with a socket a bit larger than the air valve you will expose a spring clip. Prise that out with a screwdriver - cover with a cloth so that it doesn't fly off to a never before seen part of your workshop, forever to hide there. I'm still looking.....

I need 3 hands to be able to do this :\

[Steve]

I need 3 hands to be able to do this :\

Two hands and a vise will do.

By the way, feel free to use your bike as a vise. Just slide the fork tube into the triple clamps and snug a bolt or two to hold it in place.

.

[Mike]

I've got it in the tree and I can push down the center bit (barely), but every time I try to get the clip out, it just spins in the groove. I've tried a jeweler's screwdriver, a nail, and every other small pointy thing I can find, but nothing is making a difference. How far is the center bit supposed to be able to move?

[hampshirehog]

Push the screwdriver behind the clip and pry it out - don't try and open it up or, as you've found, it'll just spin and spin

[Mike]

Push the screwdriver behind the clip and pry it out - don't try and open it up or, as you've found, it'll just spin and spin

I'm not trying to open the clip, I'm just trying to find a spot to get something behind it to pry it out, and the opening in the clip is the only spot.

How far is the center part supposed to push down?

[hampshirehog]

The centre part won't push down far - a few mm at tops. You need to 'dig' that clip out - push a sharp screwdriver against the clip and tight against the sides of the tube, about 10mm from one end of the clip, then sharply tap the handle with the palm of your hand. Some come out easy, some need a few goes. Just watch it doesn't fly off (that's why I always cover the top with a rag).

[Mike]

I'm not seeing how this can be done with one person. I'm going to have to get some help

[hampshirehog]

Pay for my air fare......

I use a deep socket on these, or you could use an ordinary socket with a short extension. A few mm thinner in diameter than the tube. Push down with this and lock your elbow completely bent / push with your shoulder (it takes the strain). That's with the left hand.

Right hand pushes the screwdriver in to position - held with extended fingers - then thump the palm down on to the handle. Pry the clip out.

You'll curse yourself when you have done it - it is easy -honestly!

[Mike]

Pay for my air fare......

I use a deep socket on these, or you could use an ordinary socket with a short extension. A few mm thinner in diameter than the tube. Push down with this and lock your elbow completely bent / push with your shoulder (it takes the strain). That's with the left hand.

Right hand pushes the screwdriver in to position - held with extended fingers - then thump the palm down on to the handle. Pry the clip out.

You'll curse yourself when you have done it - it is easy -honestly!

I'm almost positive that the fork oil hasn't been touched since it rolled off the assembly line. I had a buddy come and push down with both hands and I was barely able to pry the clip out. After I took it apart and cleaned off 30 years worth of rust and grime, it's a simple job for just me.

[GateKeeper]

now when you put it back together, see if you can use one of these and replace the old style clip you had in there, these are easier to install/remove, but will need a the pliers designed for this clip, you can sometimes get them out with a screwdriver as well

this of course if your ever going to do the forks again....