Holy fuck, that was rough. The guides and the videos show the uppers and lowers pulling apart easily. I had to clamp the lowers in the vice and use the uppers as a slide hammer and repeat the bang bang bang process for 5-10 minutes, with the seal moving almost imperceptibly as it walked it’s way out.
Putting the upper bushing back in took a trick, it is a split ring, and is expanded too big to fit in the recess unless you compress it. I found that I could take some brake bleeding hose and cut off about 4" of it, and hammer it in with a punch between the bushing and the lowers. This worked to compress the bushing, and I could then place the washer over it and hammer it down about halfway, and then pulled the washer and hose out and then drive it home.
Tomorrow I get to get back at it and tackle changing the rear tire.
Interesting. Based on the amount of force required to pop them apart, I think I’d have ended up with the uppers firing themselves through the wall. Bike is a Honda CB500F. The area where the snap ring and seal sits was corroded and rusty, effectively locking in the seals.
Yeah the rust in there can be a killer. It really shouldn’t take more than 10 or 20 psi to pop them apart. More than that the slide Hammer is probably the better idea. I have had a few pop apart by hand. All that matters is you got them apart. Never done it but probably a little lithium grease under the dust seal should keep the rust away.
Yeah, I packed the dust seal with grease when reinstalling.