classic motorcycle forum

I have finally taken the plunger out of the frame. Thank you to all members for your input.

33d6, your welt of knowledge is excellent and thank you for dropping by.

I have attached a photo of the unit. The large spring and the smaller spring are what acts like a shocker. Its sits on the rod and the sleeve. There is nothing else inside the plunger. The sleeve in my plunger has been made up by placing parts of a socket set together and then brazed and the rod after several years has got stuck to the brazed sleeve. This is not original this is a Bodged Job done by someone. Cutting the rod was the only way out.

What I need to find now is how I could get the rod made up and the sleeve made up times 2. Can any of you help with this? Thank you it has been a journey with this Excelsior.

Iansoady, thank you. I will try the saucepans on the barbie trick if I get stuck for parts. Ha HA!

Please see attached photo. Once I compress the larger spring (top). It gives me enough room on the small lower spring (bottom) to use a hack saw to cut the centre rod only. It should take me 2 minutes to do this. Yes, the plunger will have tension as the large spring is still compressed.
By realising the larger spring tension slowly and then sliding the plunger sideways to release it I should have it in my hand.

Hallo Members,
Yes, it’s been a while since I last posted. Sorry, but I had to wait for the parts book to arrive and I was hoping this will help…… it hasn’t as it only describes the parts. In the description the centre shaft and sleaves are separate and it should slide out either way. Not with mine. I believe the centre shaft is seized into the sleeve.
Which one should I cut ? The centre shaft ? OR the Springs ? Do you think the springs is from the inside of the plunger that has been taken out and then put back on the outside?
How easy is it going to be for me to replace any item that I cut?
Thank you, John. K and Iansoady and all members who have advised.

I look forward to moor replies.

Delon.

Thank you to all for your input on this.
There is no pinch bolt on this plunger as I have taken them out top and bottom. I have tried left- and right-hand plungers and they have the same symptom. I believe the rod is seized into the sleeve. If I cut the rod, I will need to find a replacement which is going to be hard for me. iansoady Yes "the vertical tube feels stuck to the centre rod". Any further advise?
Delon

Thank you, John. K and members,
Looks like my work is cut out for this project. Will let you all know how I go with  Brexit or no Brexit.

Delon

Thank you, to all members for your input on this subject.

I have spent several hours attempting to take the plunger out as per your instruction’s members. The only thing I haven’t done is cut the centre rod which passes through the frame. I am sure if I cut this, I will be able to take the plunger out. Tapping the centre rod from the bottom does not help as I believe the rod is seized. I have just managed to get a Pic from a friend of mine Alwyn. Please see attached. The instructions state that remove nut N and tap the centre rod from the bottom. This is not happening to mine plunger. Please advise further?

Best regards Delon, 

Thank you, John. K and members
From what I can understand are you asking me to compress the plunger as per the larger arrow and then compress the central shaft as per the smaller arrow? pic attached.
regards
Delon