CX500 GL500 650 Global

OK, I am finally to the point where I can get the forks apart in the restoration of my flooded GL500i. I started to take the forks apart, but am unable to get the lower allen bolt out. The bolt and the piston it attaches to just spins freely inside the fork body. I tried putting the fork back together and nothing. I even tried to drill the allen head, but it just spins. What can I do to get the bolt out so I can complete the rebuild? Thanks.

Put the spring/s back in and put the caps back on.I use a vice with cloth wrapped around the fork/s to stop damage.Then a sharp tap on the Allen key with a Rubber or Rawhide mallet.
The tension of the spring should allow you to remove the Allen bolt.I always slack off the Allen bolt as soon as I remove the bottom clamps on my CXs.
The fork seals go in with the writing towards you e.g the spring towards the bottom/oil.A piece of plastic pipe the correct diameter to tap down the seal should be used.If this is not possible a flat piece of soft wood across the top of the seal but keep it square to the forks.Also I use a bit of fork oil on the seal sides to help it tap down.

Already tried to loosen it with the forks together once the wheel came off. No dice. I will give whacking it a shot, but don't think it will work. What can I push in there to wedge the piston in place?

Wooden broom handle.

Thanks, will give that a try. Hope it works.

Sheppola wrote:Wooden broom handle.

bri,use a carpenters sash cramp to force the pressure onto the piston

Spanish Bandit, what is a sash cramp? I figure you meant clamp. Do you mean to use the clamp to press the handle into the piston?

On this picture,
http://www.cmsnl.com/honda-gl500-silver ... F++08.html

It's part number 11 we are trying to stop spinning so A piece of wood that can be pressed onto may be able to hold it enough to get a start on the Allen bolt.
Drop/spray a load of rust release up onto it and down from the top as well.I'd also be tempted to warm the bottom of the tube with a Butane torch to try and help.

I know exactly what part it is. I had the forks apart about 2 years ago, so don't think its rust, but will spray it down. Just didn't understand SB's comment fully.

bri-guy-ga wrote:I know exactly what part it is. I had the forks apart about 2 years ago, so don't think its rust, but will spray it down. Just didn't understand SB's comment fully.

sorry mate, its a toy iv used all my working life.its used by joiners to clamp up a window sash[the opening part]you need pressure on the piston greater than the resistance of the tightness of the threads
http://www.google.es/imgres?imgurl=https://www.bargaintools.co.uk/store/images/282463.jpg&imgrefurl=https://www.bargaintools.co.uk/store/index.php%3Ffilter_id%3D46%26manufacturers_id%3D23%26sort%3D5a%26page%3D5%26osCsid%3Df471edb0664047a138b4ea7671c21f7a&h=500&w=500&sz=10&tbnid=2HwstLkqU58ffM:&tbnh=130&tbnw=130&prev=/images%3Fq%3Dsash%2Bcramp&usg=__vL2pEhiG9jshiSnihGsuymoXOJU=&sa=X&ei=O0MNTK29OpOA4Qat7L2lAQ&ved=0CCAQ9QEwAg
it will push shep broomstick very tight against the piston,allowing you to undo the allen bolt