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Old 01-27-2015, 04:38 PM   #1
Chuckracer OP
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Stuck fork bushing?

So check this shit out: I pulled my forks apart to change seals and the inner bushing somehow passed through the outer bushing:




WTF?? HTF am I going to get that bitch out???
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Old 01-27-2015, 04:56 PM   #2
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Bearing puller? Like ones used on the rear axles of cars?
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Old 01-27-2015, 04:59 PM   #3
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dental hook or similiar? broom stick from the other side?
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Old 01-27-2015, 05:34 PM   #4
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There's nothing to hook or hit on the back side. It's sitting in a machined recess, much like the recess you see above it where the seal sits. Flush on the inside and well seated.
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Old 01-27-2015, 05:56 PM   #5
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put it in the freezer or heat it? maybe it shrinks less than the bushing when frozen - or expands more when heated?
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Old 01-27-2015, 06:02 PM   #6
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Yeah, that's what we're (me a my Pop) are thinking: Heat the aluminum and tap from the inside with a long dowel...or something. There is an edge there...it's not perfectly flush.

I just can't fathom how the inner bushing came out through it!
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Old 01-27-2015, 06:31 PM   #7
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similar to how the bushing is installed in aprilia oem ohlins


heat gun the outer tube and drive it out. if you dont need to replace tap it back down into position
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Old 01-28-2015, 05:39 AM   #8
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Did you heat the fork leg before pulling it apart? I wonder if the workshop manual specifies heat to ensure this doesn't happen?
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Old 01-28-2015, 06:14 AM   #9
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You could use a Dremmel and cut enough of it to weaken the material and buckle it to the inside then it will come out.

Just don't knick the stanction
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Old 01-28-2015, 08:25 AM   #10
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Maybe if you put the fork tube back in while you're polishing, it will pop out at that critical moment
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Old 01-28-2015, 08:38 AM   #11
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service

Quote:
Originally Posted by uk_mouse View Post
Did you heat the fork leg before pulling it apart? I wonder if the workshop manual specifies heat to ensure this doesn't happen?
Yes it does.
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Old 01-28-2015, 08:44 AM   #12
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This was actually the second disassembly. I had it apart once (it came apart easily - no heat, no coned washer). I was putting it back together and the seal wasn't seating properly, so I elected to take it apart again to see what was going on when this happened. Again, it came apart easily without heat, only this time the bushing stayed put.
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Old 01-28-2015, 11:04 AM   #13
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It's out. Heat and violence.
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Old 01-28-2015, 11:52 AM   #14
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First time I have a fork leg apart I tried heating it some and it needed several hard pulls before coming apart.

So on the other leg I did not heat and it came apart super easy, never used any heat since ...maybe overheated first time but its been so easy without, never had bushing issues ...yet.

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Old 01-28-2015, 12:11 PM   #15
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Just done the fork seals on the exc 300 lad it didn't happen to me !
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