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Discussion Starter #1
I am trying to dismantle the forks on my CSTL to check for staightness and replace the seals. The parts manual is not very clear.
I have removed the circlip item 27 but they do not come apart. There looks to be a castellated nut in the top of the fork leg, but if it is, it will require a special tool to remove.
Anybody been down this route before that can advise.
 

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If it is like some older bikes I have worked on, there is a section holding the oil seal that is screwed onto the lower tube that secures it all together, usually a chromed cylinder. Perhaps #23 in the drawing?? A strap wrench should do the trick.

I am assuming you have the fork leg off the bike and have removed the cap and spring? Show us a photo.....
 

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Discussion Starter #3
Picture

This is a photo looking down the stanchion into the chrome shroud, which shows the castellated tube nut inside. I'm not sure my forks correlate that well with the drawing in the parts manual. If I have the cap (item 22) there was an o-ring in a groove below it. I tried to hold the top (cap) in the vice and unscrew the stanchion, but was unable to. I didnt want to grip either part with too much force in case it isn't two parts screwed together! If you can confirm it will be a cap then I will try with more torque to unscrew.
 

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Discussion Starter #4
This is the top of the fork leg. the tapped hole is where it fits into the top yoke. Does the top part unscrew from the stanchion?
 

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I think that is just a machined groove in the tube..... It looks like you need a tool with 2 tangs that will engage that nut inside the outer tube to turn it. But I do not see evidence of threads in there?? Wish I could stand there with you to study it.

I think I would make a tool to engage the notches in that internal nut.
 

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Show you some pics from the main parts inside the fork. The are all screwed together as you can see. It is rather difficult to unscrew the bottom end which fixes the wheel axle. And it is much more difficult to unscrew the the part which is chrome plated. I hope you can understand this, my English is not so well.
 

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Discussion Starter #8
Johann, Thanks for the advice. My forks are different. The parts manual is for 1955 and 56 which look similar to yours. Mine are 1957. Does anyone know how to get hold of a parts manual for the later 1957 model?


I made a tool and unscrewed the shroud, but the inner fork stanchion still doesn't want to come out of the fork leg. There looks to be an additional seal. The top of the fork has a brazed inner part, so I don't think that is removable. I have been advised against using the leg as a slide hammer as it could deform the inner bush making it impossible to remove. I may try putting the whole thing in tension as I don't see anything else to unscrew.
 

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Discussion Starter #11
Thanks ddmv. They look the same as my forks and the CSGT parts manual from the bike museum library shows them. How did you remove the seals item 32 and 33? Can you just pull on the stanchion to extract them with the upper bush item 31, or is there another way?
 

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That's how you do it on modern forks....just yank the inner tube and the seals come out.
 
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