[LITEITUP]

I just started to tear my forks down to replace the springs and oil. How do I seperate the tube from the lower fork housing? I pulled the dust seal right off but the main fork seal I cant seem to get out of there. I tried to do it like a slide hammer but nothing.

Also, the 'drain' bolt at the bottom of one of the forks just spins. I cracked it loose, started to unscrew it but noticed whatever is on the otherside/inside is spinning. I tried to hold the spring and rod then unscrew but it still spins. Whats up with that? How do I get it out? btw, wow was the oil black!

[LITEITUP]

Well I managed to get the tube out by using the sliding hammer method, just slammed it harder than I did.
BUT I still cant get that bolt out the bottom off the other fork. I tired to put everything back together then try and loosen but nothing. Is it possible to remove the tube and seal without removing the damper rod and spring? I was thinking if I did that, I could get something to grab the bottom on the rod to try and get the damn bolt out.
Anyone got suggestions? I really need to get these forks done to help me get on the track. My last resort would be to take it to a dealer which I would really rather not do.

[A.F.T.C.T.T.G.]

Originally Posted by LITEITUP

Well I managed to get the tube out by using the sliding hammer method, just slammed it harder than I did.
BUT I still cant get that bolt out the bottom off the other fork. I tired to put everything back together then try and loosen but nothing. Is it possible to remove the tube and seal without removing the damper rod and spring? I was thinking if I did that, I could get something to grab the bottom on the rod to try and get the damn bolt out.
Anyone got suggestions? I really need to get these forks done to help me get on the track. My last resort would be to take it to a dealer which I would really rather not do.

If you have never taken a fork apart before, don't have the proper tools to do it, and don't have a service manual which show you in steps how to disassemble a fork.... find a friend that has all of the about and can do it... or take it to your dealer.

You damn sure don't want a "failure due to mechanical error" occurence on this part of your bike while you're riding it

[LITEITUP]

I never have no but Im pretty mechanically inclined. And yes I have a factory service manual but that doesnt help me out. The problem Im having and how they say to fix it is not working. Soooo thats why Im trying to figure it out posting questions here at fireblades.org. I trust myself for the most part. Ive completely disassembled my F3 when I wrecked/repaired it and I change my own tires and balance, etc.

[Absoluteg]

Ill have to go through the same thing ... I hope you took some pictures so i can see, what goes on. If i happen to catch up or finish before you do, ill be glad to post some pics and notes. Ill be getting the service manual tomorrow, so ill be posting some shortly.

-G-

[Absoluteg]

So i disassembled the forks. The fluid looked like muddy sludge, Nasty stuff. I cleaned it out w\ some WD40 ... which did an excellent job. Im looking at the Honda service manual (which gives great directions) and it looks like i need to replace some copper bushings, which ill but at the dealership tomorrow. Im having trouble getting the fork tube out and also the bottom screw (which i rounded off by accident). If anyone has any suggestions on how to remove the fork tube or that stripped screw.... i'd appreciate.

-G-

[LITEITUP]

Well I think you have to remove the screw first before the tube will come out. That sucks the screw is stripped. If I were you I would just drill off the head of the bolt. Then you could use the tube and lower as a slide hammer to get the tube out. Yes, it will come out, just gotta slam that bitch hard. Then once the tube is out you can get the remaining screw out the damper.
I finally received my parts from ronayers, not thier fault but Honda's backorder. I bought all new o-rings, both sets of copper bushings, and a couple other parts. Got my springs in from racetech as well. All I need is some fluid and Im ready to assemble.

[Absoluteg]

Thanks for the advice ... This bike broke my budget already, i just wanna get it back on the road, but i dont like to half a$$ what i do. So ill buy some drill bits and ... hopefully get the forks done. Thanx again

-G-

[Absoluteg]

So i put the bike back together (after installing new bushings & seals), then bam ... they're leaking out all the fluid from the top of the fork. I took em partially apart. looks like i might need another washer on the top of the fork seal. Is that normal ? I did install the washer under the seal (like to book said). Im sure if i install another washer on the top, that would stop the seal from moving.

[ohi stopthat]

Having a **** time at the office, or so it seam's. I only ever use "real" Honda seals cos ive had more than enough with pattern bits, you did put them in the right way up ? Yea iv'e done that as well.
As for getting the bolt out when the allen key is stripped, I flog in a spline drive bit and use an impact driver. If that fails then I reach for the power tools.
Dont give up !!!

[Absoluteg]

Yea... ive got all of the work done ... i know the seal isnt on backwards. I did chip up the aluminum w\ a chisel, getting the original seal out. Ill definately keep trying,.