CB500 Fork tube won't come off

[pendulum]

https://ccgi.pendulum.plus.com/gay1.jpg

Can't get the fork tube off to change the seal
The Haynes says Pull It... I've tried, won't budge.
I tried soaking the seak in penetrating oil too but nope.
I filled it with boiling water and hit the top with a mallet to try and pop the seal off, but nope.

Any ideas before I give up and take it to a shop to get done properly

Also... when removing the top bolts and the springs, I was careful to lay everything out in the order that it came out.

This is how one came apart:

https://ccgi.pendulum.plus.com/gay2.jpg
I removed the top bolt and there was that washer there. I pulled the spacer upwards, and the spring came with it... it was kind of attached in a wonky way to the spring. Didn't seem right. From looking at the manual it seems there should be a spring seat between the spring and spacer.... there wasn't... but I'm wondering if that 'washer' is the spring seat, and the last person to take it apart put it above the spacer instead of under it? When I took the second fork apart, there was no 'washer' or 'spring seat' at all! So one of the forks had the 'washer'/spring seat in (maybe in the wrong place?), one of them didn't! So I'm missing a part at the very least!

I also think I read in Haynes that the side of the spring with the most coils should be at the bottom, well both of them were facing the top (skywards)... but I'll double check that in the manual. Anyone know if the springs are the correct way up in the photos?

Thanks
____________________
1998 CG125 (Sold) CB500 [+ Clio 172]
Usually_Wrong: I tend to fail more than pass. [Speaking about Theory Practice]
Usually_Wrong: im on unemployment at the moment

[jjdugen]

Install with the more open coils at the bottom, then washer then spacer.
Have you removed the bottom damper retaining bolt? Its an allen head and usually mad tight To remove it, re-assemble the spring / spacer and tighten the top cap, this will give you better purchase on the damper bolt. A 'rattle gun' will make the job a doddle.

Once that bolt is out, grip the bottom leg and the slider in each hand and really yank them apart. It might take a few goes (ensure that the seal retaining circlip has been removed!). You will also pull the top bush out in the process, inspect it for wear or damage, replace if in doubt.
____________________
The CBR900RR has been sold. Aprilia Falco worms its way into my heart.
Try Soi 23 on Amazon for a good read.... Self promotion? Moi?

[pendulum]

https://ccgi.pendulum.plus.com/gay3.jpg
Good shout. I'd been a complete idiot. I managed to slacken both of the damper bolts earlier (was a struggle) but didn't remove them Can't even follow simple tasks with the manual right in front of me

Removed one and it came apart first pull
I ordered new top and bottom bushes. They look ok (so does the damper rod and seat etc, fortunately I don't think I damaged it with my incompetence). But I will change them (the bushes) anyway.

Thanks

Do you or anyone else know what I should do about the 'spring seat'/washer situation?
____________________
1998 CG125 (Sold) CB500 [+ Clio 172]
Usually_Wrong: I tend to fail more than pass. [Speaking about Theory Practice]
Usually_Wrong: im on unemployment at the moment

[stinkwheel]

There should be a washer between the spacer and the spring on both sides but none between the spacer and the end cap.

It's called a "Plate, spring joint". Honda part number: PFKL654643 but at a fiver each, I'd suggest going to a fastner shop and finding a washer of a similar size.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[pendulum]

Brilliant. Thanks again.
____________________
1998 CG125 (Sold) CB500 [+ Clio 172]
Usually_Wrong: I tend to fail more than pass. [Speaking about Theory Practice]
Usually_Wrong: im on unemployment at the moment

[Budgetboy]

Ok heres a few tips for you..
order the new washer the same time you get the bushes & seals.
While you are at it order 2 copper washers for the 8mm allen key bolt that you just undone.The old ones sometimes leak if used again.Not worth it for how little they cost.
While the forks are apart, make sure you clean the inside of the fork leg and tube. Old oil and crud will contaminate your new oil so best to do it right now.
Give everything a good clean..
When you re assemble make sure you do it in a clean environment. And follow your manual. Read twice, do once.
Good luck
____________________
www.Mailorderrepairs.co.uk We service your Carburetor's, Calipers & Suspension for less Also Bike repairs undertaken.

[pendulum]

Thanks chap.
Already received the oil seals/dust seals/bushes etc, but I will get hold of the 2x new damper washers and the 'spring joints' or equivalent as suggested. No point skimping on them. Hopefully be back on the road on the bike by Tuesday or Wednesday (still have the car but it's not the same )
____________________
1998 CG125 (Sold) CB500 [+ Clio 172]
Usually_Wrong: I tend to fail more than pass. [Speaking about Theory Practice]
Usually_Wrong: im on unemployment at the moment