Fork Tubes - Won't go back up through top clamp - Help Please!

[ChucksKDX]

I removed my fork tubes for new seals/oil and now I can't get either one of them to go back up through the upper clamp tube hole. Taking them out, I did have to twist slightly while pulling down. But trying to get them on, they go easily through the bottom clamps on both sides, but for the life of me, I can't get them started up through the top. See pic for where they stop (basically at the top of the little lip going into the top clamp from the bottom). This is on both sides. I put WD-40 on them and have tried twisting as I push up, but I can't put enough upward pressure to gain any ground getting them started (on either side). I'm pushing/twisting so hard, I'm going to lift it off my jackstand. This is the point where I usually get frustrated and do something stupid/tear something up. So I thought I'd ask more educated people before I did that this time. Any help you can provide would be greatly appreciated. See below pics.

Thanks,
Chuck

IMG-9813.JPG (1.59 MiB) Viewed 2408 times

IMG-9815.JPG (1.99 MiB) Viewed 2408 times

IMG-9814.JPG (1.99 MiB) Viewed 2408 times

[SS109]

Make sure the bolts are fully loose then use a flat head screw driver to spread the clamps apart from the side just a bit. Trust me, it won't take much!

[KDXGarage]

Take them out.

Clean off all the oil from the forks and clamps.

Use a pry bar to slightly wedge them apart. As mentioned, it won't take much!

[ChucksKDX]

Thanks guys, I appreciate the input!

Chuck

[pumpguy]

To spread the gap in the top clamps, what I did is to use the clamp bolts as jack screws to spread the gap.

To do this, insert a piece of steel, washer or whatever, that just fits into the gap but not so far as to go out into the bore where the tubes go. You do want to cover the bolt holes in the gap. Do this for both bolt holes on each side.

Next, take your clamp bolts and thread them in from the back side so they just make contact with the steel insert pieces. With the tubes in position as shown in your pictures, tighten the jack bolts just enough to spread the gap so the tubes will go all the way through.

This jack bolt method of spreading the gaps will exert a lot of force, so don't go crazy with the tightening. Use just enough force so the tubes will move through, but no more.

Hope this helps.

[KDXGarage]

Hey! That's a good idea. It would give one a free hand also, besides more precise.

[SS109]

Honestly have never heard of, or thought of, that little trick pumpguy. Excellent!

[ChucksKDX]

Next, take your clamp bolts and thread them in from the back side so they just make contact with the steel insert pieces. With the tubes in position as shown in your pictures, tighten the jack bolts just enough to spread the gap so the tubes will go all the way through.

That sounds like a great idea, thanks!

What's the difference in a 'clamp bolt' and a 'jack bolt'?

Thanks

[pumpguy]

Next, take your clamp bolts and thread them in from the back side so they just make contact with the steel insert pieces. With the tubes in position as shown in your pictures, tighten the jack bolts just enough to spread the gap so the tubes will go all the way through.

That sounds like a great idea, thanks!

What's the difference in a 'clamp bolt' and a 'jack bolt'?

Thanks

Same animal, just a description of function, how its used.

[ChucksKDX]

Okay, great thanks for the help!