SR125 Fork Seal Removal

[DanceLikeAMon...]

Me and my stepdad are in the middle of trying to replace the fork seals on my SR125. I have the forks off, removed the cir-clip and am now at the brute force bit of removing the stantion from the fork.

Have been trying for ages, but nothings budging (apart form the workbench and vice)

I did a search on here and someone said they managed to seperate them by forcing the seal that's already in there. We tried this, but all we have is a mangled up, jammed seal, and the parts still won't seperate.

Please help!!!!!!

[Git]

Have you taken the bolt out that holds the two bits of the fork together? if you turn the fork upside down you should see a bolt, this bolt I think should be screwed into the damper assembly inside the fork, if this bolt has not been removed the two halves will not separate, if this bolt has been removed ignore me

[DanceLikeAMon...]

Ah! We haven't taken any bolts out. How do you get to it? Do you just need a very long screwdriver?

[Git]

The bolt we speak of can be turned from the outside by allen key or whatever bolt it is, but the bit inside the fork, ideally a metal rod with the ends shaved down is my preferred tool to hold it, although there is a way of using a wooden broom handle to hold the bit inside although this is a bit, erm, naughty

[Frost]

yes you have to remove the Damper bolt from the underside of the forks. its normally an Alen bolt. Put in the alen key length ways, then put a bit of pipe or and ajustable spanner ont he end and turn.

I had to use a huge amount of force on mine.

Ones thats done and you have the two fork halves, put a spanner in under the fork seal and lever it out. this too takes a fair bit of force and wil wreck the seal in the process of removal.

The rest is simple after that

[DanceLikeAMon...]

Just before I do any damage, can I confirm that I am working on the right bit. If I look down the tube, it looks like a bolt head about 12 inches down (this is in the tube that had the spring and long spacer in it). Is that what I should be removing?

This is what I have: (ignore the 12 inches part, I don't know why I stuck that on!)
https://img.photobucket.com/albums/v158/dance_like_a_monkey/seal.bmp
Is that little bolt head in the middle of the picture the part that I should take out?

Why the f**k didn't Haynes say anything about it???? Got I hate that manual![/img]

[Frost]

should be something like this. the damper bolt is normaly a fair way in (up to 2 inches)

Once its undone you will be able to pull the to haves apart

[DanceLikeAMon...]

So the end that has the damper bolt head is the same end that the wheels attach to? I was looking in the other end, and the only bolt I could see was half way down the tubes!

I have given up for the night , it's too dark and cold, but will look for that tomorrow!

[Frost]

yup the damper rod runs up the middle of the spring.
I thought you might have been looking at the wrong end, hence the diagram

[DanceLikeAMon...]

Aw nuts! My stepdad has been out playing with it again (the fork that is!) and says there is definitely nothing at that end to remove, twist, tighten, turn etc. So the only possibilty is that bolt about 12 inches down the fork slide!

Is this maybe something specific to the Yamaha and I need to buy a special tool? (it's the 2001 model)

Snip: Here's photos of the bottom of the fork. Anyone see something I could be overlooking?

https://img.photobucket.com/albums/v158/dance_like_a_monkey/motorbikes011.jpg
https://img.photobucket.com/albums/v158/dance_like_a_monkey/motorbikes004.jpg
https://img.photobucket.com/albums/v158/dance_like_a_monkey/motorbikes003.jpg

[cagiva gezzer]

https://216.37.204.202/Yamaha_OEM/YamahaDB.asp?Type=13&A=167&B=20

Me thinks its like the old style rockshox mag/quad series where a circlip holds the seals, then the bushes/spacers are forced in VERY snuggly to hold it all together.

By the position of the rebound spring, I would say so.

I KNOW ITS NOT THE SAME BIKE, but it illustrates the point. A very useful sight with microfinches of loads of bikes.
____________________
"because one stroke isnt enough and four strokes waste two"

[DanceLikeAMon...]

[cagiva gezzer]

Means they are removed by brute force.
____________________
"because one stroke isnt enough and four strokes waste two"

[DanceLikeAMon...]

Ah I see. That is what the Hanyes manaual says, but it was held in a vice and there where two of us tugging it. The workbench was being lifted off the ground we were pulling so hard and it still wouldn't budge. There is defintely a feeling of it being held in place buy something.

Ah well, looks like it's a trip to the mechanics for me!

[cagiva gezzer]

Try a series of short sharp tugs. Check the microfinche and make sure there isn't any bolts in the bottom of the stanchions.

An idea that always seems to solve problems! Get an heat gun and try heating up the lower legs. NOT BURNING THE PAINT OFF, just warm it up and try and utilise thermal expansion,
____________________
"because one stroke isnt enough and four strokes waste two"

[DanceLikeAMon...]