Front fork oil seal. 97-2641- BSA starfire

[Spaceman]

I've not assembled one of the early shuttle valve forks before but my best understanding of the inside profile of the seal holder is shown. If not correct, could you please say how it differs?

[Dunc]

Dear Spaceman,

Thanks for the drawing as to what it probably should look like
Having now established what it should be then I think that what may have happened is that i have managed to lever off the rubber section of the fork oil sea alnd left the metal part of the fork oil seal in situ. Hence this metal part of the old fork seal is hampering any possibility of fitting a new oil seal,since the remains of the seal  creates  a rim which protrudes  and thus hampering fitting a new one.
I will have a go at the fork holders tomorrow and see if there is any movement of what I believe is the metal remains  of the old fork seals. Maybe you can see this upper rim on the pictures? 
I see it as a binary process in so much it either works or doesn't and if there is no movement then I would end to buy new holders.
Much appreciate the time and trouble that you have taken to assist me.
Let's hope that my assumption is correct?

Cheers  Dunc

[Spaceman]

I think you are saying that the metal outer case for the rubber seal is still in place inside the seal holder? If it was, I would have thought the remains would look to be as in the sketch below whereas your last pic might possibly show the side wall of the metal seal cover but it doesn't appear to show the roof section that covered the top of the seal?

If the metal seal cover was still in place then the only way to remove it if it can't be knocked out using a drift from underneath is to use a Dremel to grind away a groove in one side to allow it to then be collapsed inwards.

[Dunc]

Dear Spaceman,
Yes your latest drawing shows the situation that I think has occurred.
As you say if it does not respond to being drifted out then I would have to make a groove in the metal and hopefully that will give me some space to get it out.
I will keep you updated on developments but I suspect that it may be quite well rotted into the holders and resistant to being drifted out. I probably will be spending a bit of time fiddling around with it.
Thanks again
Dunc

[Dunc]

Dear Spaceman,
Quick update.  A spot of heat and they drifted out with a bit of effort.
Pic attached showing what came out.
So onwards and upwards,  a new set of seals and I will crack on with rebuilding the forks.

Like many things in life it was good to bounce my problem around and hopefully if there are others who read this and find themselves in the same position then this may help?

But yet again a massive thanks for your help in solving the puzzle for me.

Cheers
Dunc

[Spaceman]

Well done - we got there in the end

If you don't already have it, the link below is for the 1969 B25 parts book which is invaluable for not only finding part numbers but also gives you a good idea of how things go back together:

https://www.bsaunitsingles.com/Archives/Spares/BSA%2000-5197%201969%20B25%20Starfire%20x.pdf