OzVMX Forum
Clubroom => Bike Talk => Topic started by: Doc on September 01, 2007, 04:55:13 pm
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Houston we have a problem! I've a pair of RM250z/d forks I seriously wish to dismantle but the previous owner/s have really butchered the fork caps and I simply cannot move them. They are the hollow air cap type hence the hex part is far from being hex anymore so regular sockets or spanners are as good as useless.. Does anyone know any little tricks that may help in removal of said caps? I have a small pipe wrench that may work if I really persist but in doing so I feel I am being butcherous..I have a pair of replacement caps ready but getting the old ones to move is the problem..any ideas?? and no! I don't want to buy a honda! ::)
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Id prolly grab the hacksaw mate and saw a nice crisscross into the tops and find a piece of plate that slips in nicely and use it like a huge screwdriver . That should budge them. If you can "Make" a large phillips head you can get twice the leverage and twice the contact point
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I'm visualising :P; but, notch them with an angle grinder, insert flat bar and turn ;).
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If you have replacement caps just drill 2X5mm holes tap to 6mm,put 2 short bolts in ,over one bolt put the ring of a big shifter and turn. :D
HTH
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Thanks guys! Pokey I actually went back to the garage and tried exactly the method you stated..actually I am still in the process of grooving but by all intent and purposes it looks like it might just work ;) Lozza your idea is now classified as plan B..plan C is abort the mission :D
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Shear bliss at Suzuki Central as Plan A works!! ;D looks very ugly but eh, I'll keep 'em on the shelf for spares cause you just never know :D
(http://i12.photobucket.com/albums/a205/Doctor_Suzuki/cap.jpg?t=1188637270)
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"Ochams raiser"
Why make something more difficult than it need be ;)
Great stuff mate.
dont forget i still have a pair of PE forks with your name on them. , I can drop them over sunday arvo on my way back down from caloundra if you like.
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Actually I did forget! Sunday works for me 8) maybe by then I'll have a second problem sorted..getting the bloody wiper holder and seal out of the lowers with the inner still in..I had to give up for tonight as I was losing it ::) I know it's persistance that is required as I have done plenty before but I just thought maybe, just maybe there might be some ground breaking new 'easy' method I didn't know about :P
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Thats Next sunday mate i should have said, am working tomoz.
Id be dropping the leg to get it out and save whats left of my sanity if any does still exist, then locating my ergonomically bent screwdriver. If they dont pop out after the circlip is removed after a few pumps i call it names then drop the leg off.
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no worries bloke! I reckon it's gonna take me till next Sunday to do the forks anyways! The legs are off, I find an old triple holds them better than clamping in a soft jaw vice :) I'll get back into it today after I've had my Weeties™ ;D
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Doc
The fork tube SHOULD remove the seal and wiper when removed unless others >:( have removed the C ring at the bottom .
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yeah that's what I figured oldfart but she has not moved a fraction of a mm even with a little heat involved :-[ I figured a few good pulls on the inner with the retaining bolt and snap ring removed should pop out the lot but alas, it is not to be..zee most stubborn fork seal I have ever come across ::)
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Doc
Wrap some duct tape around the alloy -stand upright form a good seal then pour some brake fluid and let it sit overnight and see if that works ;)works for me
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no probs Oldfart, sounds like a pretty good plan, I'll give that a go and attack it again tomorrow :P you'll hear me from home if it's successfull and if it's unsuccessfull you'll hear me from Sydney :D
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:o oh poo!..well Oldfart, I took your advice and let the seal wallow in brake fluid for near 24 hours and guess what? :-\ the seals are still as stuck as ever. Someone from the Yahoo RM/TM group recommended using the same method but trying carb cleaner instead so I'll have to give that a go now ::) I have NEVER seen such stubborn seals in all my born natural :P any other ideas? I've tried yanking and yanking, I've added heat to the equation, I've now tried brake fluid..I feel plan C is now imminent unless the carb cleaner works :'(
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hello doc,
I have forced seals out by filling the forks with oil all the way to the top and putting the cap back on and then compressing fork in press.
You can improvise the press by strapping the fork upright under something and use a small jack underneath.
The downside of this process is the oil mess you end up with when they pop out.
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Doc,
I'm a bit of a late comer to this problem of your's, but am I to assume you have removed the dampening rod bolt at the bottom of the fork leg before embarking on this exercise? And removed any clips holding the seal in place? And put the axle lug on the fork leg in a BIG vice?And you have pulled on that tube with all your 65kg might? It could feel solid for the first few pulls but it should loosen.
I have never had a fork seal stick before.
That was a little to freudian even for me.
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Hmmm.
grab some diesel and some Ammonium nitrate from a cow cocky or gardening supplies store and pack the inside of the fork with that stuff.. err no durries while ya doin this mate . Now soak a bit of hemp rope in kero and stuff that in the hole for the bleader valve.
prolly best if you do the next step out the bush and put your postal address on both the upper and lower legs .
Now get a match and light the rope get on ya bike and ride like hell and wait for the big boom ;D
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get a blow torch and burn the seals out? or if your afraid if flame wipe some PVC pipe blue glue and light it, it will melt them out with a slow flame - the seals are rooted anyway right ?
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well another day in paradise has seen the mighty brake fluid trick work like a dream. I thought I'd give it another go this arv and it came apart just like I'd imagined it would..or at least should have 4 days ago :) thanks Oldfart! I can now get on with this smelly job ::)
Don't worry freaky, the oxy thought had crossed my mind on the 3rd day as did a thermite attack similar to Pokey's idea just not quite so explosive :D
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Why not take the leg out? ??? ???
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Why not take the leg out?
Lozza that is what I was trying to do. The legs won't come out before the seal due to the design of the internals. They are not like the earlier models where it is possible to simply undo the allen screw and it slips apart. I had already pulled apart one of the 250Z legs and it took all of about 2 minutes but this second leg (seal) just didn't want to play the game hence I had to ask thinking maybe I was missing something. I was missing something..the extra 11kgs of body mass that Evo thought I'd weigh ;) 54kgs ringing wet just doesn't cut it in some instances but in others it's a bonus ;D
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Next time Doc get your pup to pay tug of way with it. he must be pushin close to 70KG ;D
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maybe you shoul start eating dog food Doc ;)
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:D he'll prolly bite you next time you're over for insinuating he is a porker! come to think of it, that's probably better than having him try to shag your leg like he does most other visitors..he just loves TMWilliam ;D
Evo, I reckon you maybe onto something there..they say My Dog is made to tempt fussy eaters..I'll give it a go ;D
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Its all muscle and charisma im sure ;D