Fork Seal Removal

[Rob Neal]

Hi Everyone. I've removed the fork seal holders from the forks on my A65 but can't get the old seals to budge.  I've used heat and penetrating fluid to release the grip between the seal O/D and holder but no luck.  Looking at it from the end with the slots for removing the holder there's not enough of the seal shoulder to get a purchase on to drift it out.  Question is, are the slots for the holder removal tool 'blind' or are they through slots?  If the latter it means I can get the drift on to the seal and tap it out.  Don't want to hammer away at this until I'm sure.  If this isn't the way to do it, any advice on how to get the buggers out?  Many thanks again!  Rob

[Spaceman]

You haven't said what year your A65 is. If pre-1969, the workshop manual recommends using a special tool from above which is basically the correct size drift to engage with the seal but to miss the internal flange. If 1969 or later, the seal is just drifted out using a small drift from below.

[Rob Neal]

Sorry, didn't mention the year because although the bike frame number defines it as 1962 it has been upgraded/modified over the years as many bikes have.  For example this one has an 8' TLS front brake, external fork springs under the gaiters, a headlamp rather than nacelle and a twin carb head.  The forks may be original 1962 with a modified brake, but I don't know.  From what you've said though, and taking a good look at the seal holder it looks as if they are the earlier forks and I'll need the special tool.  Thanks for the help as always. Cheers. Rob

[Spaceman]

Special tool 61-3006 for removing the earlier fork seals is just a large diameter drift - if you measure the required diameter from looking at the seal holder, I'm sure you could find a correct size socket to do the job.

[Spaceman]

On reflection, the special tool may not work in the way I assumed but may simply rely on the projections on either side engaging with the seal through the cut-outs in the internal wall. If so, all you need to do is to use a small blunt drift to knock out the seal through the cut-outs.

[tige]

I have one of those seal removal tools if you want to borrow it, i can post it to you if it will help.

[Rob Neal]

Sorry for the (very ) late reply, been tied up with a few non-bike issues of late.  Getting back into the garage I read all of your replies and decided to have a go at making the removal tool. I used an old piece of scaffold pipe, skimmed it on the lathe to get the OD correct and then cut in the tangs to engage with the seal holder slots which worked well.  I  also came to realise that that the old seals can be drifted from the 'top' side as the slots for the removal tool are machined through. Every day's a school day as they say.  Fitted the new seals and reassembled the forks, so good to go.  Thanks as always for the advice.  Rob