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Front forks. Hex bolt not coming out!

Discussion in 'XJ Technical Chat' started by wrenchmonkey, Mar 20, 2015.

  1. wrenchmonkey

    wrenchmonkey Member

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    I have an 1981 Seca 750 (XJ750RH). I'm having a hard time taking the front forks apart. The hex bolt at the bottom will not come out. It just spins when I try to rattle it off. Am I missing something or what?
    Any suggestions are welcome.
     
  2. FtUp

    FtUp Well-Known Member

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    the hex bolt has Loctite on it and you have to hold the other end with I think it's a 19mm hex key. you can us a reversed spark plug socket if you can stick an extension in it backwards. there are several threads on the forum that discuss it.

    FU
     
  3. k-moe

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

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  4. FtUp

    FtUp Well-Known Member

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    good points, you don't want top mess with the temper on any of that metal either. I just did one of the forks on my 750 maxim and out of the 4 of the 5/8 spark plug sockets I have only one was reversible. it is a craftsman socket, not sure if you could buy a current craftsman socket and get the same thing though.

    FU
     
  5. k-moe

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

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    I cut one of mine with a die-grinder to make it reversible.
     
  6. FtUp

    FtUp Well-Known Member

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    that was my next option.

    FU
     
  7. MiCarl

    MiCarl Active Member

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    There are several other tricks you can use to make a tool:

    1) Short bolt with a couple nuts jammed on it. Drop in and turn with a socket.
    2) Threaded rod with nut welded on each end. I have one of these in my tool box. In my case one of the nuts has been re-ground so I can use it on other forks.

    I don't know the thread size. I've got a couple of the tools I made and don't remember which one fits the XJ. If FtUp is correct about 19mm it'll be a 1/2" bolt or threaded rod.
     
  8. FtUp

    FtUp Well-Known Member

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    my '83 750 maxim is 19mm, and iirc all the xj forks are 19mm.

    FU
     
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  9. Rooster53

    Rooster53 Well-Known Member Premium Member

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    For some reason the 750 Seca is different and the 19mm tool will not work.

    upload_2015-3-21_10-9-36.png


    upload_2015-3-21_10-4-30.png

    upload_2015-3-21_10-5-36.png
     
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  10. Polock

    Polock Well-Known Member

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    damm sam, look at them pictures, those are great!
    heating the bolt is making it uncomfortable to touch, not smoking or glowing orange
     
  11. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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    The XJ750 Seca damper rod (and the XJ1100, too) do not have an inside hex in their damper rod head to allow the use of the tool........on the 750 Seca, you are supposed to put a thin object (6mm allen key, small Phillips screwdriver shaft, etc.) into the upper anti-dive housing access port (AFTER removing the anti-dive unit from the fork) and that object will go thru the "oil lock valve" (a/k/a taper spindle) and then thru one of the ports in the damper rod, thus locking the damper rod in place, and then the damper rod bolt can be removed.
     
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  12. k-moe

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

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    Why is it that I always seem to forget about that!? Len is exactly correct. Thinking back, I did not need to do that for disassembly, but did reassemble the forks using that method.
     
  13. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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    The HCP4402 Damper Rod Retaining Tool, listed further below in the "Fork Tools" section of parts, is needed to hold the damper rod itself (to prevent it from spinning freely) while this damper rod retaining screw is loosened and removed:

    small end fits XJ550 all, XJ650 all, all XJ750 Maxim/Midnight Maxim
    large end used on XJ700 all, XJ750-X, and 900 all
     
  14. Beekman

    Beekman XJ Grasshopper

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    Not sure if this applies to your bike based on the procedure chacal just described (mines an '80 maxim) but I freed my hex bolt by getting 2 people to pull the inner tube outwards from the outer leg to hold the damper rod somewhat, and hit the hex bolt with an impact gun.
     
  15. wrenchmonkey

    wrenchmonkey Member

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  16. wrenchmonkey

    wrenchmonkey Member

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    Nice. Thanks for the info!
     

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