I am in the middle of chrome fork slider swap and have run into a couple of problems. I cannot get the seals back in, I am trying to do it with the forks still attached to the bike as I cannot get them off. I have removed the caps at the top, I have removed the pinch bolt, sprayed BP blaster on the mounts they slide through and it will not budge. I have only worked on the right side so far so I don't know if the left will be the same way.

Am I missing something?

 

Try this...
Put the slider on the floor protected by something that wont mare the finish...
Get a piece of PVC Tubing that fits the ID of the slider like 1.5" dia.
Cut square and slightly buff to a finish so you wont tear up the seal...
Now take the seal and lubricate the seal with some fork fluid to help it slide into the slider...
use the PVC to persuade the seal to seat properly...
Once the seal is in place you then can install the retaining clip that keeps the seal in place...

Now after the seal has been installed its time to slide the slider onto the tube...
Besure there is fluid on the seal where the tube will come into contact with the seal so there is nothing there that would scare the seal and allow it to leak...

think of this being in 2 steps
the insallation of the seal and then the installation of the slider...
should help
If your still having problems send me a PM and I'll send you my cell # and you can call me if you are having problems...

 

if i understand correctly.
the forks are still on the bike.
pinch bolts loose/removed.
top bolt off.
1-i had to place a socket the size of the hole inside the hole in the top tree.(were you removed cap) and gave it a slight tap and it then slid out..may 2 ot 3 taps...a bit of rust built-up around edges of the caps was holding it in place.. ***mark placement /orientation of pipe before removal..so you will not forget..(did it on an evo road king)
tip- use old seal as cushion when tapping the new seals into pipe.
2-change-out the beer cans/ cans on top of sliders to chrome while you are doing all this or it will not look right.
3-on a bagger , the beer cans/ cans on top of sliders will not give you enough room to replace seals with-out removal of tubes...unless things have changes..
4-make sure to zip tie the brakes to the engine guard ..they are known to slip and hit the fender during rebuild.
5-pump front brake several times when all done...repeat pump front brake several times..or you will not be able to stop the first time.
best of luck!

 

You need the slider off the tube to have enough room to successfully install the seal, at least I did anyway.

 

I always seat the seals with the fork tube still in the tree. I just push the seals most of the way in place with my finger tips and then use two blunt wooden dowels, pencils or whatever 180 degrees from each other to push the seal home. I do this on baggers, Softails, whatever. If I need to replace the upper tins, I just spread the bushing apart at the bottom of the leg and slide the guts off so I can slide the tin can off the bottom.

I learned to do it this way from an indy buddy. Back when the Dressers had air on the front forks, it saved a ton of time. You could use the air set up and a shop vacto suck the new fork oil back in.

 

Thanks everybody, I knew I needed to get those off becasue I kept hitting my hand on the upper. Now I have messed up the little "oil stop" after it fell off and I squished it inside the slider. Hope that is a replaceable part and hope one of the six dealers in my area have one. Anyone happen to know the part numer for that little piece at the end of the inside slider?

 

A tip with that is to put a dab of grease on it to hold it onto the forktube while installing the slider. Sorry, don't have a part number right here handy.

 

I did but I was getting pissed and ramming the slider up and I guess it fell off and took the the brunt of my tantrum.

 

You have to take the fork tubes off the bike so you can reinstall the clip that is right above the seal. Chances are if you forced the old seal off you got the clip wrapped up in it.

 

Sorry, but you don't.