Broken circlip in front fork

[jacobarber]

I've been doing some work on my new 82 CB650SC. The left fork needed a new seal. I started taking the fork apart and ran into an issue when the circlip that holds the seal in place decided to break. I was using the proper tool, but it's a 29 year old piece of hardware. With only 1 eyelet, I tried to grab hold of the other one and slowly pry it out. The slightest pressure busted the 2nd eyelet off as well. I'm now stuck with a circlip in the fork with 0 eyelets.

How the hell do I get this thing out? I can't drill new holes in the circlip since the fork pipe is still inside the slider. Would it be safe to drill into the side of the slider so I can push the circlip in from the outside? Suggestions are welcome

[mikefootusa]

Man, I don't envy you!  One of my circlips was corroded and rusty, and quite stuck.  Broke two circlip pliers end tips and wound up buying new pliers, but I got it out (but didn't replace it...just cleaned it up with a wire wheel).

I don't know why you can't drill through the slider (lower fork) as there it no pressure there...but it will still be tough to get that clip out....drilling through the middle of the clip would allow you to take it out in two pieces...but that is hard material.

[TDodge7]

I would try and get something behind the circlip in the little channel it rides in, like one of those multi bend mechanic picks that looks like one of those evil pointy tools the dentist has. Might needs two of em and another set of hands so you can apply pressure to one end of the circlip while you try to pick the other end out of it's channel, otherwise it might just spin in it's channel.

[jacobarber]

I just read a post on another motorcycle forum from a guy that had the exact same problem. He solved it by digging at the seal underneath til he could get a better grip on the circlip and slowly weasel it out. Guess that'll be my best chance. Will throw an update up once I have one.

Thanks for the suggestions friends.

[jacobarber]

This circlip is being awfully stubborn. I spent a few hours last night trying to cut the seal out from underneath the clip, only to discover that the seal has a good deal of metal that I can't get through. I ended up drilling a small hole in the side of the slider so I could press the circlip in from the outside. I had to quit before I could get it out, but now I'm considering another problem.

There is some relatively heavy pitting on the fork tube. The huge majority of it is sitting above where the fork bottoms out, but some of it definitely moves past the seal. Without a lot of work getting this thing smoothed out, the seal is just going to fail again eventually.

I'm considering just grabbing a set of good condition forks from ebay and calling it a day. I can get a set for $55 shipped right now, which is a negligible price to make this bike complete again. I may just do that and see if I can repair the damaged fork to sell later on or just use as a backup.

Any thoughts on this plan?

edit: I bought the forks. $60 shipped (not $55) still is very reasonable for forks with good seals and no pitting. I'm still under $1000 for this bike and have learned quite a bit about wrenching it. Can't wait to get it back on the road with properly setup suspension and a functional rear brake. Woohoo!

[hppants]

Glad to read this is working out.  I would have bought the used Ebay forks too.  However, do consider replacing the fork oil and at least inspecting the seals before you stab the forks.  Maybe take one of those plastic do-ickies and swipe the seals clean.

[jacobarber]

I've already put that on my to-do list before installing them. The tool is like $3, so I think I can afford that.