trying to rebuild forks, i CAN NOT separate the fork top and bottom

[kilabeez0]

I removed the forks, removed the top caps and drained oil, removed the springs inside, removed dust seal and then the spring clip. Manual and online instructions say to just pull the bottom and top apart.....yea right. I had the bottom in a vice clamped down pulling in and out as hard as i could on the top half of the fork and it wont budge. O I almost forgot, I did loosen the 6mm allen bolt on the bottom, however it doesnt come out, just loosens. can anyone help me? :confused:

[200xman]

Put the springs back in and install the cap. This should give you enough tension to remove the allen bolt completely. Then, use the upper fork like a slide hammer and pop the 2 apart.

[grundlegrabber]

200xman is right, that's what I do with mine. The allen bolt won't come out because the piece inside is spinning. You will need the tension to hold the inner piece so you can get the bolt out completely. Then do the slide hammer thing.

[Dirtcrasher]

I removed the forks, removed the top caps and drained oil, removed the springs inside, removed dust seal and then the spring clip. Manual and online instructions say to just pull the bottom and top apart.....yea right. I had the bottom in a vice clamped down pulling in and out as hard as i could on the top half of the fork and it wont budge. O I almost forgot, I did loosen the 6mm allen bolt on the bottom, however it doesnt come out, just loosens. can anyone help me? :confused:

You'll see why once you get them apart, that bolt goes into the damping rod in the fork. Like the guys said the spring holds tension on it or use an air gun. Lots of other forks have a tool that holds the damping rod internally while you loosen the bolt on the bottom.

[kilabeez0]

yup, you guys were right. I figured that was the problem so before anyone replied I actually grabbed the bolt carefully with needlenose pliers and pulled it out. What a PITA that spring clip was. I had to grind down the tips I had on my spring clip pliers so it would fit farther into the holes. Otherwise it kept popping right out of the hole.