K1 front fork disassembly??

[j1mmy]

I'm stuck trying to dismantle the front forks on my K1. I dumped the oil out but don't see any way to remove the long post that goes down inside the lower fork (by the tire). I bought new seals and the clymer manual doesn't explain well enough for me to figure it out.

One fork goes in and out, spins around but the other one sticks if I turn it and sticks part of the time when I try to pull it out, push it in. What does this mean? How do I get them apart to replace the seals? thank you.

 

[j1mmy]

I figured it out. Once I got the chrome sleeve off I could get to the retaining clip and seal. I did verify the restriction I have is definitely the inside of the lower shock but I'm not sure what to do about it. I was able to feel a tiny bur and I tried to hone it out and its much improved but there is still a problem. Anyone run into this?

 

[69ST]

I've not run into internal problems with these, but anything is possible after 35 years+. Usually what I find is rust on the upper, external portion of the upper fork legs and lots metal filings inside the lowers...with varying amounts of dirt. I like to thoroughly clean the internals. Mineral spirits and a long bottle brush, followed by a blast of Brakleen & compressed air work wonders; just remember to pre-oil everything prior to reassembly. If you find a burr, then it makes sense to smooth it out. However, I'd be extremely hesitant when it comes to removing any material from the sealing/articulating surface of the inner fork leg. Get the fork completely dismantled first to determine if it's really necessary.

Once the C-clip has been removed, the rubber seal can be pried out (carefully) or pulled out with a small pick/hook. You're going to replace the seals anyway so the only concern is not nicking the fork leg. Once the seal & clip are out, the fork leg comes apart easily. Believe it or not, the seal and C-clip are all that's retaining the fork leg. What the hey...it works.

One caveat: don't remove the lower screws from the lower fork legs. These are plugs which, once removed, are very difficult to reseal.