High-G FJR Junkie!
Join Date: Jan 2013
Location: Millgrove, ON, CA
Tonight I can't look at your pic....... I'm a little confused... you already have the new seal in and the forks jammed? Shoulda only happened while you were slide-hammering them apart... here's the deal.....
The middle bushing has to be unseated with the lower bushing while slide-hammering it apart. That part happens easily. The upper bushing is an interference fit like I haven't seen on other bikes, and is a bear to unseat (along with the old seal).... so you MUST (very highly recommended at least), heat the lower fork tube in the upper bushing area to expand it or help loosen the bond, then slide hammer it out.
What happens is the lower bushing being a smaller diameter can go inside the middle bushing and expand it to the point of jamming inside the tube.
Now what.... BIG RUBBER hammer and beat the fork tube back down or put it in a hydraulic press. All such that you won't damage the fork tube at the top end (thus the BIG RUBBER hammer). May have to repeat.....
So if you already have the new seal in, and if the lower bushing is now somehow got jammed in the middle bushing again (there should have been no reason to slide that tube back up, so that's the part I don't understand), you will have to beat the fork tube back.
There is a chance the middle and/or lower bushing is now damaged (by the lower bushing), and you should now repeat removal of the upper bushing and seal, replace whatever and re-assemble. You should be able to re-use the upper bushing and the seal.
I do all my fork work with the forks clamped horizontally in a good vice. Perfect alignment when slide-hammering contributes to all this jamming... try not to be perfectly lined up....... and don't worry, you ain't the only one......
It has been debated about leaving the middle bushing out as its function is questionable (Gen 1 never had one). I'll leave that up to you.
Keep yer stick on the ice....
2014 FJR1300A - Root Beer (sold)
2009 CBF1000A - Sienna Red
1999 VFR800Fi - Pearl Shining Yellow