07 Front Fork Maintenance

tschutter · 2025-01-21T19:30:24-0500

Tonight I'm jumping into rebuilding my front fork. I'm to the point where I need to remove the inner (upper) sleeve from the outer (lower). I've removed the retainer clip (see in picture). I'm slamming the inner sleeve upwards to remove it like I've seen on YouTube and now it is stuck such that it won't return in so I can pull it again.
Suggestions?

RossKean · 2025-01-21T19:53:19-0500

Did you heat it before starting? Best to NOT slam too hard or the middle bushing can get stuck under the upper. I think I would warm it up with a heat gun where the upper bushing resides and see if you can get it to go back down. I got one of my forks stuck the first time I did one. Seems to me that a 2 x 4 was part of the solution...

Also, have you read the most excellent article by FJRed - currently residing at FJR-Tips.org

https://www.fjr-tips.org/maint/ForkSeal-BushingReplacement.pdf

Note - the link on the site has a typo which I have brought to Mark's attention. (Busing instead of Bushing) The above link will get you there.

Good luck.

Auburn · 2025-01-21T20:17:44-0500

warm the area of the middle bushing (just under where the fork seal was) with a torch, use MAPP gas cylinder for best results. Only need to heat for about 10-15 seconds moving all the way around the lower fork tube middle bushing area. It will become too hot to touch in that short time. If the tube comes out, and the middle bushing is still in there, I describe how I get the bushing out here in post #14

https://www.fjrforum.com/threads/reluctant-fork-tube.175465/#post-1408160

07 Front Fork Maintenance

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