The above is the parts diagram for the front forks. Getting the oil seal housing to unthread from the oil tube was the real battle. It needed a proper “special tool” to engage with the internal nut and twist it free. So I made one—because clearly BSA thought I’d have a full machine shop hidden in my garage. Files, grinding wheels and a hacksaw maybe.
Today was the day. I clamped the sliding tube in the vise so the welded nuts stopped it from spinning, slid the tool into place, and gave it a heave with my trusty plumber’s pipe wrench. With a creak, a groan, and maybe a few muttered words my grandmother wouldn’t approve of—it finally broke free. A wee victory!
Ideally, the tool would have a neat little T-handle welded on top. But in my case? The pipe wrench was my kilted Highland dance partner for the day. Functional if not elegant.
The second fork was a bit more stubborn. No surprise there—like brothers, one’s always more difficult than the other. I wandered over to the neighbour’s with it, applied a bit of gentle heat (translation: persuaded it with fire), and with some extra persuasion it finally let go. Another win.
With the circlip removed, the shot slid right out of the sliding tube. Off came the nut at the end, followed by bushings, shims, clip ring, and the oil seal housing. It all came apart like haggis at a Burns supper—messy, but satisfying.
Now all the parts are laid out in their own boxes, ready for inspection. New seals will be a must, but the rest will get a thorough cleaning before deciding what’s salvageable.
New seals will be a must, so two can be ordered right away. The rest will get a proper cleaning and close inspection before I decide what’s fit for service and what’s headed for the bin.
At least nothing went flying across the garage today—so I’ll call that Scottish progress.