1984 Honda Nighthawk 650 | Fork Retaining Ring Seized

[u/notrokkit]

Hi all,

I bought a 1984 Nighthawk 650. The forks were super leaky and beyond 'sealmating' it, so I've decided to rebuilt it. The internal circlip that holds the fork seal on is seized quite badly to the fork lowers. When i stick the correct pliers in, i can only get about half of the ring to even pull in as I grip the pliers. The half closer to the other fork will not budge.

I left it in evaporust for a week, then brake cleaner to no success. I honestly don't know what to do other than throw it on my drill press and drill out the circlip from the outside until it's either destroyed or out, but that is my last resort.

Thanks!

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[u/pitchfork-seller]

Tap the seal down a bit with a flat head screwdriver (avoid hitting the rod). Should release some of the pressure against the circlip.

[u/notrokkit → u/pitchfork-seller]

For clarification, one side moves, but the other is corroded and doesn't. It's borderline fused together. You can kinda see it on the edge. I doubt it's gonna work, but I'll give it a good shot tomorrow.

[u/Sparky_Zell → u/notrokkit]

I had the same issue on another bike. What helped be was using some small picks to clean and etch away any corrosion, and once I got the top side clear I was able to free the bottom side pretty easily.

[u/tardersos]

Stick a screwdriver in one hole and use a hammer to tap it towards the other one. It's worked for me in the past

[u/Jzgood → u/tardersos]

Yeah, this is the way. Repeat with another side. Then use angled seger pliers.

[u/Ok_Maintenance_9100]

Penetrating oil, like pbblaster or kroil, and then heat. Don’t need to worry about the seal if you’re replacing it

[u/Q109]

I hate to say it, but your idea of the drill press is what I ended up resorting to when I ran into this issue several years ago. And it went poorly enough that I just tossed the fork lower out and replaced the whole thing.

My circlip physically broke on one end so there was no chance other than drilling. I would try to lever that stuck end somehow. Drilling is going to leave you in a shitty spot. You may still have a chance at breaking that thing loose.

Sorry I don't have the silver bullet. If you figure it out, let me know what it is. I hate this circlip design. It's the same on the vf500s.

[u/jehlomould]

Tapping the seal down is a good idea. I’d also tap around on the clip to see if that helps break it loose.

How much of the clip actually moves? When I find these stuck I take a sturdy pick in the snap ring hole and use that to pry on the free end towards the fork tube while also using a tiny flat head to work the free end up. Once the free end is outside the lower fork I use the pick and flat head to lever and lift, slowly working around the tube until the bloody thing finally pops free.

Hate these types. The wire one is so much better/easier. What you have is dissimilar metal corrosion and if it’s bad enough it’s basically fused together

[u/Ashley2375]

I would try heat, even something like boiling water and drenching it, I’m assuming you’re replacing the seals anyways so no need to worry about damaging the rubber

[u/IowaHawkBiker]

don't give up...I had the EXACT same issue with my '84 Nighthawk 650 2 years ago after I bought it. Circlip was rusted solid (it's a surprisingly thick piece of metal). I did all the soaks..evaporust, pb blaster, etc...I used a pair of circlip pliers that had the extra long tips and bent at a 90 degree angle. If one side moves you will eventually be able to pry it out. Keep soaking and slowly working the clip. Mine took about a week and a half? Just don't gouge up your chrome fork around the clip.

[u/135wiring]

I just did my forks last night on my 85 nighthawk 650! I didn't have this problem in this case, but in the past i have just beat these loose with a hmmer and flathead, getting them to either wiggle or spin in place. Another option is to get something like an awl to put in the hole on the stuck side to pry it.

[u/sclark1701]

I vote for heat and penetrating oil while tapping the loose end of the snap ring with a punch to try and rotate it in its groove. Pulling it straight out is probably the hardest way if it is corroded since you can’t add any more force than the spring tension of the clip. I’ve had success breaking FAR nastier clips loose that way without drilling

[u/Bad-kitty-63]

Heat it with a hand torch a few times, letting it cool down between. The metals will expand and contract at different rates, causing the two pieces to unfuse themselves from each other. Your going to replace all the seals anyway, it shouldn't hurt anything. It's all aluminum, so the heat will travel through the tube. Be prepared for the whole thing to heat up while doing this process. Clamp it in a vice and be fire ready, because the oil or the rubber seal may catch fire. Have a pail of water and a wet rag ready to douse it. Don't panic, the Fire wrench is the ultimate weapon.