Topic: Looking for tips on separating this fork!

[Tugboat]

First, I left it on the bike, completely intact. I hit it with an impact driver and that didn't work. Then with an air impact driver and that didn't work either - the bolt just spins. I took the fork off the bike, flipped it over and, using my weight, compressed it fully against the ground and hit it with the air driver... spins. I drained all the oil and took the springs out and tried to jam a broomstick against the plunger - no dice. Out of ideas. Anybody have any recommendations?

[Duanob]

If its that stuck you may have to drill the head off and take the internals out and deal with it another way, like an easy-out and a vise or something. Or if there isn't anything wrong with it just leave it and change the oil and ride on before opening a can of worms. You can still change seals with the tubes in the lowers. its a bit of work but it can be done. Pull the circlip, drill a couiple of screws into the seal and pry them out. Be careful installing the new ones that you don't rip the lip on the seal, use a long piece of 1 1/2" ABS plastic pipe cut at 90 degrees to set the new ones in place.

[ekpent]

Try putting some duct tape or other material on the end of the broom handle so it can bite in and get some "traction". Worse case scenario if you drill the head there should be a stub left to get a grip. Have you lubed with penetrate and hit that bolt with some heat to help yet. May be more of just the shoulder of the head corroded and sticking to the fork bottom and not the threads.

[bjbuchanan]

Drill the head off and be done with it. Quick trip to home depot bc they have the right length and pitch grade 8 caps there. Once apart figure out why all the tricks out there didn't work

Its easier to drill the cap screws bc they center the bit nicely

[Duanob]

Don't forget to replace the copper washer:

http://www.ebay.com/itm/like/271214259522?lpid=82

It's no wonder these bolts get stuck mixing three different metals together like that. Alum. Copper, and steel.

[kerryb]

I wrapped the top of the broomstick in blue nitrile rubber gloves from harbor freight, then put the broomstick in a clamp on the floor so I could push down and turn at the same time.  It worked on the first try.  Maybe mine wasn't as stuck as yours.

Good luck...drilling is always an option.

[Tugboat]

Finally got it apart. Had a buddy come over and help me fully compress the fork while I hit it with the air driver. Came right out! I guess I wasn't compressing it enough. Thanks for the tips guys!

[tomkimberly]

If you drill, use left hand drill bits.

[Duanob]

If you drill, use left hand drill bits.

huh?

[Stev-o]

If you drill, use left hand drill bits.

huh?

Remove a broken bolt using a left handed drill bit

[grcamna2]

Tug,
        a Suzuki damper rod holder tool w/ a T-handle extension should hold.It's a long T-handle tool extension w/ a 3/8" sq. dr. on the end and you have your choice of a couple different tapering square bits to fit into the hole in the top of the damper rod.I think K & L Supply will sell them.The trick is having that 1 extra pair of hands  to hold the other end as you use the impact,a vice is essential.