Help Can't seperate Lower Leg from Stanchion

Zofo

Zofo

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The oil seal on one of the forks was leaking so I am replacing both. Did the non leaking one no bother, but I cannot seperate the Lower leg from the Stanchion. The other one came out no bother with the slide hammer action.

The bike is a 92 R100R

Any Ideas please
 
I had this before, I think this bike uses the K forks

There's a bush at the bottom on the shiney bit 12 (stanchion or slider I always mix them up) and if you don't change the fork oil regularly, the contaminents behave like an abrasive and wear the bush dramatically quicker than normal!!!

The bush gets thinner and then spreads open and when you try to extract it??

They didn't chamfer the lower edge of the maching on the fork and the bush catches and binds and You will NOT get the leg out

The last 2 I've had like that I had to cut the alloy lower and buy a replacement

Bush 13 is the cuprit

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It's obvious I know, But have you made sure you have removed the circlip from the top of the oil seal?

.
 
Thanks Jaytro

That is much more than I expected, a bit of a sickner really.

I will price a new lower leg.

I have tried heat but that did'nt work

Thanks for your prompt reply on both forums.

Val

I have removed the clip ring and gouged out as much of the rubber seal as I can. I think this could be a long process of pulling and swearing
 
Zofo said:
I have removed the clip ring and gouged out as much of the rubber seal as I can. I think this could be a long process of pulling and swearing
Click to expand...
Tell ME I bet you can't get it to go right back down to where it was either??

If So you have the same problem as I had the bush has deformed and folded over the botom edge of the fok leg

BUT you should be able to buy a lower off Motorworks or Bins or Sherlocks? I think even off BMW the last time it was only £40 but that was 3 years ago

Doesn't matter if it's dirty cos you can clean it well before you fit the new bits :aidan :aidan :aidan But It may only be marginally cheaper?
 
You can remove the seal without taking the lower leg ( slider ) off.

Pull it out and up the stanchion. Replace the new one by sliding it down the stanchion.

BMW make a special tool for replacing it this way ( i have one ;)), it slides down the stanchion, and hits home the new seal.
 
The fork stanchion works perfectly right down to the bottom. When I try to slide it out it get stuck in the bush or washer. I think I can see the bush coming up on the inside of the lower leg wedging the seal. I cannot move the seal or the bush they seem ceased together.

I am using head and trying to work out some bits of the seal. This is followed by alot of brute force and ignorance. It was suggested to me to put the axel back in and use it to anchor the leg for pulling purposes, I will try that. I emailed motobins for a price for the lower if all this fails or if I dislocate my back first.

Thanks for your interest
 
If you think that part #13 (the bush) is expanded and is not allowing you to pull the slider off, you may be able to use three of four very thin feeler gauges, insert them past the seal and let the bush ride up on them and hopefully they will act as "ramps", compress the bush and you can pull the slider off.

good luck!
 
Thanks Solo Lobo

The bushing is rammed up against the inside of the tube, pretty well jammed.

Thanks for your suggestion
 
Those bushings are split to ease install, haven't ever seen one seperate enough to stop someone from taking the fork appart....

can you drive the leg back down to free the bush from where it's seized and try again with the shim method?
 
The bushing and the seal are one, they are wedged together. That is a good point that the bushing is split, there must be some give in it.
 
Have you tried knocking the bush back down/home, then having another go at removing it?:nenau
 
Thanks Val I will try that, I have been riding my GS 1200 for the last week and will get back to repairing the R100R
 
Eventually got them seperated. A combination of gouging out the rubber seal, a head gun and putting the axel back in and pulling like you know what.

Thanks for all your help and encouragement
 
Nippy Normans supply Touratech, Wunderlich, Desert Fox and many other makes of accessories.
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