Wilsons Sandbox

The only way to get to the fork bushings is to take the forks apart.  I use an air impact gun to spin the bolt with my right hand and with my left hand I push the fork upper and lower sections apart, holding on the upper part with my hand and pushing away with my thumb the lower part.  This puts pressure on the damper rod that this attaching bolt is threaded in to.  The pressure on the damper rod will hold it enough that you can give the air gun several short bursts and this should get the bolt to come out.  Just don't spin this bolt unnecessarily since you will damage the sealing washer.   Good luck, Fred www.arrowheadmotorsports.com     [b]From:[/b] jctegler@... [b]Sent:[/b] Sunday, July 18, 2010 10:32 PM [b]To:[/b] dsn_klr650@yahoogroups.com [b]Subject:[/b] [DSN_KLR650] Fork Separation Anxiety   Howdy, Oh wise list. I am trying to separate my forks to replace the seals + bushings. It appears those 10mm allen bolts at the base of the forks have become glued to the aluminum tubes. They will not rotate as I thought they would until locked in place by the fork tool. Attempting locking them in place with a homemade tool(threaded rod and tapered nuts) is not working either. Tonight they are soaking in penetrating fluid and tomorrow I will try and turn them again. I have heard of blowing ther fork seals out with air pressure. I just wonder if this would also allow me access to the bushings(which are to be replaced.) Thanks for any conferred wisdom. Jim A5 __________________________________________________________

#ygrps-yiv-714602167 p {margin:0;}I've always found that an impact wrench and a high-quality allen socket does the trick. -Jeff Khoury

----- Original Message ----- From: "Jim Tegler" To: "dsn klr650" dsn_klr650@yahoogroups.com> Sent: Sunday, July 18, 2010 9:32:20 PM GMT -08:00 US/Canada Pacific Subject: [DSN_KLR650] Fork Separation Anxiety   Howdy, Oh wise list. I am trying to separate my forks to replace the seals + bushings. It appears those 10mm allen bolts at the base of the forks have become glued to the aluminum tubes. They will not rotate as I thought they would until locked in place by the fork tool. Attempting locking them in place with a homemade tool(threaded rod and tapered nuts) is not working either. Tonight they are soaking in penetrating fluid and tomorrow I will try and turn them again. I have heard of blowing ther fork seals out with air pressure. I just wonder if this would also allow me access to the bushings(which are to be replaced.) Thanks for any conferred wisdom. Jim A5 __________________________________________________________

On 19/07/2010 16:38, Jeff Khoury wrote:

> I've always found that an impact wrench and a high-quality allen socket does the trick. > > -Jeff Khoury

Jeff don't forget the 2 ounce lump hammer (Birmingham Screwdriver) I wonder if a little heat would help? This is the reason why its nice to go around the bike taking every external nut and bolt off and applying a certain amount of copper slip just to ward off the corrosion pixies. Jack

On Tue, 20 Jul 2010 18:28:39 -0000 "SM" writes:

> Hit it with the mig this morning, just like Fred said. > > Easy peasy > lemon squeezy. > > Thanks > CA Stu > > PS Got any red hot tips for installing the new one? I tapped it in > there flush with a hammer, ran out of time and had to head to > work...

<><><><><><><><> <><><><><><><><> CA Stu, My red hot tip is to freeze the race and heat the steering head. I like spit hot on the steering head if I can get it that hot. Then use the old race as a driver since it'll be shrunk and not get stuck in the recess. You can also make an installation tool with some all thread, nuts, washers and the old race. Just tighten the all thread and pull the race into place. Glad you got the old race out so easily. Best, Jeff Saline ABC # 4412 South Dakota Airmarshal Airheads Beemer Club www.airheads.org The Beautiful Black Hills of South Dakota 75 R90/6, 03 KLR650, 79 R100RT . ____________________________________________________________ Penny Stock Jumping 2000% Sign up to the #1 voted penny stock newsletter for free today! http://thirdpartyoffers.juno.com/TGL3141/4c466be733c6b7919dm07vuc