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Fork Seal change issues

Discussion in 'XJ Technical Chat' started by AVAD, Aug 12, 2017.

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  1. AVAD

    AVAD New Member

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  2. Toomanybikes

    Toomanybikes Well-Known Member

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    So what's the problem?
    And what model of bike?
     
  3. AVAD

    AVAD New Member

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    I am changing the fork seals on my '83 750 Midnight Maxim. I am stumped on how to get the top off. Most articles I have seen suggest pushing on the top to release a clip. This one has a nut on the top. Am I able to turn this to remove the top cap? I have pushed too, but no luck. I also didn't put all my weight on it for fear of damage. Which is the correct way please? The top pic is what the top of my fork looks like.
     
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  4. Toomanybikes

    Toomanybikes Well-Known Member

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    That is the unscrew type top cap
    Put lot of penatrating oil on it first
     
    Last edited: Aug 12, 2017
  5. AVAD

    AVAD New Member

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    sorry, but to be clear, I cannot screw this one off, I have to push to put pressure on it to reveal the clip inside.
     
  6. Toomanybikes

    Toomanybikes Well-Known Member

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    No there is no clip on those ones. The forks with no nut shape are the push in and clip type.
    17or19 mm 6 point socket .
    I have an 83 xj750k here with same top and they are screw in ones
     
  7. AVAD

    AVAD New Member

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    very good, then lefty loosey I will try. Thanks
     
  8. mlew

    mlew Well-Known Member

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    It is much easier to loosen the screw on caps while the forks are bolted in the triple tree. That's an easy way to hold them, those caps can be a hard to loosen if they have never been taken apart. bolt them back in and use the handle bars as extra leverage to hold while breaking them loose.
     
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  9. AVAD

    AVAD New Member

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    Thanks for the tip, I think I will be trying it
     
  10. k-moe

    k-moe Pie, Bacon, Burbon. Moderator Premium Member

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    And take your time. If they don't move at first, apply penetrating oil (as mentioned) wait a few days, and try again. Repeat as necessary.
    The last thing you want to do is round the nut off.
     
  11. AVAD

    AVAD New Member

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    Ok. Got the top nut off the forks using the triple tree for a clamp. Worked like a charm. Now, I can't get the bottom allen bolt out. The inside keeps turning with the bolt, even when I put the whole assembly back together for pressure on the parts. Any suggestions? Or can I just pick at the oil gasket to get it off and replace with the new one. I know I won't get to inspect the other pieces, but my main goal here was to change the rubbers.
     
  12. Chitwood

    Chitwood Member

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    I haven't been into my forks yet but I'd say you're already this far. Do what's necessary and tear them all the way down, inspect, and replace parts as necessary. Then when you put it back together you will know that everything is good to go up there
     
  13. XJ550H

    XJ550H Well-Known Member Premium Member

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    insside there is a rod it should have a nut shaped receptical that you can use a sparkplug socket upside down on an extension to hold it then remove bottom screw . you may want to heat the screw at bottom as it has strong loctite on it heat will soften it .if you do not have nut shape you use a broom handle to hold it in place then remove screw from bottom.
     
    Last edited: Aug 12, 2017
  14. XJ550H

    XJ550H Well-Known Member Premium Member

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    you can rent or buy this tool
    HCP4402 Aftermarket DAMPER ROD RETAINING TOOL. This long aluminum tool, with proper sized nuts on each end, is used to retain the top of the fork damper rod (in the bottom of the chrome tube) when removing or installing the damper rod retaining screw. One end has a 19mm hex and the other end has a 22mm hex, so it will fit all styles of XJ-series bikes except 1981-83 XJ750 Seca and XJ1100 models. This tool will make the disassembly of your upper tube from the lower tube much easier!
    I purchased one and it works well
     
  15. XJ550H

    XJ550H Well-Known Member Premium Member

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    when you remove the fork seal heat it up with a heat gun it will come out easier also the top tube will not just pull out on this model bike you can use it to pull the seal like a slide hammer

    second choice is to pressureize the tube untill the fork seal blows out along with all the oil in the tube.
    drain oil first
     
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  16. Toomanybikes

    Toomanybikes Well-Known Member

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    Easier way is loosen everything first leave top cap on and spring will hold damper rod. Then use air gun to remove bottom bolt.
    Have done dozens of forks this way and never had to use a "tool" to hold damper in bottom of fork I have one that sits unused in my toolbox( got it in Kawasaki special tools kit about 20 years ago)
     

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  17. XJ550H

    XJ550H Well-Known Member Premium Member

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