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This is the first time I have ever attempted to change the fork seals myself. I followed the steps in the fork rebuild post and the first fork came apart with ease. Started on the second one and for the life of me I can't pull the tubes apart. When extending the tubes to pull them apart it gets fairly tight then loosen off again about 2" from the end (fully extended).
Any advice on how to pull them apart?
Also what could be the problem? (tubes or bushing)

Thanks,
Matthew

I'm assuming that you've removed the retaining clip???

Use the two like a slide hammer, don't be afraid to really bang them apart.

Chances are you've got a bad bushing that's hanging up. Make sure you inspect them and replace as needed.

It's good practice to be cautious when separating the tubes or you're likely to damage the bushings.

If they don't separate with one or two decent pulls, take your heat gun, propane torch, or even hair dryer, and heat the bottom of the upper tube where the seals and bushings are.

Not too hot, just warm to the touch, this will allow the metal to expand enough to safely and easily separate the tubes.

I personally heat them up a little prior to trying to separate them the first time.

Tattp77 wrote:This is the first time I have ever attempted to change the fork seals myself. I followed the steps in the fork rebuild post and the first fork came apart with ease. Started on the second one and for the life of me I can't pull the tubes apart. When extending the tubes to pull them apart it gets fairly tight then loosen off again about 2" from the end (fully extended).
Any advice on how to pull them apart?
Also what could be the problem? (tubes or bushing)

Thanks,
Matthew

I'm better the retaining clip wasn't released.

What was the outcome?

Thanks for the help guys. I got it apart finally. The guide bushing was catching on a ding on the outer tube. I saw the mark before and didn't think nothing of it (knowing nothing about the inner works of the forks). I'm guessing this is what started my problem.
Is there anyway to remove the ding from the tube? or am I looking at buying a new one?

Thanks,
Matthew

I've successfully removed them with an Arkansas stone and polished them out. I've also done a real nice job chucking the tube in my lathe and polishing with a Scotchbrite.