Topic: SL350K0 Forks....how to get the damned things apart?

[fendersrule]

So the forks are off of my SL350K0. They are drained. The 21mm chrome caps are off. I pulled out a spring from each one. I also removed two cir clips on each one, the small one that deeper inside, and the large one that holds the seal in place.

I can't pull the tubes out still. Am I missing something? I've rebuild 3 forks before, but they all were CB450/750 which had the rod which came out with the oil lock piece. Yes, I've read the Honda manual, but of course it doesn't mention something that I'm clearly missing.

Do these forks actually require the seal to be out before the tubes can separate from the fork legs? That sounds like a very risky endeavor....none of the other bikes required that.

I guess the manual says to remove the seal before removing the pipe. How the heck do you get the seal out (safely) with the pipe still being in there?

[754]

Not sure but if seal circlip is out and fork does not pull out try this,push fork in, then pull up sharply, if seal starts to move..continue till its out.

[fendersrule]

Yea, I haven't really "YANKED HARD" on it yet...I feel I'm going to score something inside of it.

Oh also, I did remove the JIS screws (1x each fork) on the bottom of the forks.

Sounds like you're saying that seal is the next step...I certainly am not going to try to cut it out with a sharp tool.

[754]

If they don't undo from the bottom,  then they come out the way I described..

[fendersrule]

Your the man 754. 3 "knocks" is all it took for it to come out.

Probably will took the fork bottoms to Honda and have them measure the diameter. I have a tool for measuring the pistons.

[754]

Wipe em off slide together.. Check for wiggle...throughout its travel.
 May be able to take some wear out by making or using new bushings..

[fendersrule]

Well, on one fork, the whole assembly pulled out, like it should, which is good.

One the other fork, the piston is stuck at the very bottom inside of the fork leg. Not sure how to get it out. That means that somehow, the piston managed to slide over the surrounding clips...

I "could" have Honda measure the pistons, but the piston that I do have out shows fine horizontal and vertical scratches. I cannot feel them with my fingers, but I can see them. I'll have them measure the fork bores, but you can't buy those new, so what's the point? I mean, even if they are out of spec, there's nothing I can do....just get new pistons and slap them in there?

Let me know what you guys think on how to best proceed without "overkilling" things.

[fendersrule]

Here's a picture of one fork's piston wear:



Here's what pulled out of the other fork:


Piston is still in other fork:


Good condition stuff; just needs a cleaning:


Thoughts?

[754]

Maybe circlip broke or came off.
 The weather lines..that is the way they would wear, dirty oil,  may have been part of it.
 If the fork legs Are quite worn, bthen stock bushings may no time tighten it completely up, in that case, making and fitting custom bushings may help.

[fendersrule]

Thanks 754.

Sounds like this is out of my league. Who would you recommend me dropping this off to? Any reputable honda/motorcycle shop?

What price would I be looking at you think?

Maybe Hondaman is the man for this….

[FuZZie]

You may need to fab up a treaded extension look at the attachments but sure it's not enough reach on it's own. 
http://www.ebay.com/itm/New-Blind-Hole-5pcs-Slide-Hammer-Pilot-Bearing-Gear-Puller-Removel-Kit-/170931421601
Should at least give you some ideas.

[fendersrule]

Thanks guys. I've PMed Hondaman and Bill Lane. Any other members here that could possibly kick some butt on this?

[HondaMan]

Do you think the ring clip and piston are still down inside the bore? Can you maybe see them with a flashlight or such?

There's not a lot of wear showing on the one piston you do have, that's about light wear compared to most. If the other one's clip fractured, that may be what is holding it down in there?

[fendersrule]

Thanks for the reply HondaMan. You may have the tools and expertise that I lack.



It's good to know that the wear on the piston is light. If I had a Mic I would check the bores and the pistons. if the other one is in the same shape, maybe it's worth just refilling them and replacing the seals?

But, to get what you see out…hmm…. I see the c-clip in the back

[fendersrule]

Well, got it out just by spraying some brake cleaner, and taping it for a little while.

Hmm..




Option 1: Quit being a baby and throw it back together with new seals and fluid. Replace the broken cir-clip (somehow).

Option 2: Get it mic'd, possibly replace pistons, etc.

I cannot feel any wear with my fingers on the pistons.

[fendersrule]

Well? Any insights? Again, I've never rebuilt "piston" forks before. Can I just through it back together with some fresh fluid and new seals and call it a day?

[FuZZie]

I know I'd be getting 2 new clips a redo would kind of suck.

[fendersrule]

Yeah. Maybe even 4 new clips.

Those are NLA though....argghh

[754]

Look on ebay for some clips, may have to buy a whole fork, a single side may be reasonable.
 Those deep scratches in the fork shown, is the other one better than that? It may affect damping.

Basically, clean everything off, slide together, check for excessive play.

[HondaMan]

The clips are a common industrial part: Honda just quit carrying them because they probably don't use them in anything built recently. They aren't "special" other than being the right size when they come in a Honda envelope (at a Honda price!).

Take a look at MSC Supply (www.mscdirect.com) or other hardware providers for new ones? I do this when I'm rebuilding real rusty things. Once in a while, I stumble across the right parts at Ace Hardware(!) here in town, too.

[fendersrule]

Thanks Mark.

I've been VERY busy with my other CB450 (check out the steering bearings thread). I could use your insight as I think I finally figured out the problem that some people are having with fitment issues….and it's all because of the ridge that Honda puts underneath the tensioner nut. For the CB450, that makes direct contact with the top steering bearing/seal. That will raise the height of the upper stem and easy 3-4mm…

Back to topic:

I will remove a "good" clip from these forks and go down to the hardware store and replace them all.

Is it your opinion that the pistons are good enough to throw back in? I spent some time yesterday and couldn't feel any of the scratches on the pistons. It all felt smooth to me.

[fendersrule]

There's actually three different types of clips per fork. Hopefully the hardware store (Fastenal) will have them?


Here's a downer. One fork tube is in fantastic shape. The other one….has a gash. You can feel it with your finger:



If I align the fork base to the bottom of the tube, it puts the gash only a couple inches up from the seal. Not good. So what to do?

[754]

If the seal won't hit it don't worry about it.
What are you cleaning the forks with, they look all scratchy.

[fendersrule]

I haven't touched the fork tubes yet...that's probably just residue.

How far can the fork tube travel down the base of the fork leg? That will give me an idea of where the gash is from the seal.

[fendersrule]

With the fork tube aligned with the bottom of the fork leg, the "gash" is about 1.5" up from the seal.

I guess that puts me in the clear.