Fork Caps Out!

Finally got the fork caps removed from my XJ650RJ. I'm the original owner of this 20K bike and am bringing it back to rideable condition after almost 15 years of storage.

Months of soaking with PB Blaster and Liquid Wrench did not do the trick so I followed advice found here and got some Kroil. A week later with daily treatments of Kroil and some creative fork compression got them to finally release. A memory jogger was also there when I found PVC spacers for the Progressive springs I installed many moon ago.

Thanks to all who post advice and experiences here, its been most helpful with this rebuild. Len at XJForever has made all my needed parts available in one place and I have now rebuilt the carbs, brake MC and calipers as well as installed great-looking black SS brake lines. The brakes have never been so solid.

Now to repack the wheel bearings, clean the top of the fork tubes and replenish the oil, mount some new rubber and get those carbs tuned. I'll be back on the road!

Cheers,

 

REPLACE the wheel bearings (they're cheap) adjust the valves THEN get the carbs tuned. You'll probably destroy the bearings removing them anyway.

You did check the rear brake shoes for delamination, right?

(Removing rusted-in fork caps was how I discovered Kroil too.)

 

Just checked the brake shoes, no evidence of delamination, thanks for the tip.

Good advice on the front wheel bearings although my light use of a brass drift punch probably did not harm them I know it's generally good procedure to use new if readily available. The grease was "chunky".

Do you recommend replacing the rear bearings as well? The grease was still very pliable and the bearings smooth. The old, dried-out rear tire was a @#!&! to get off, not much flexibility left in it.

What about the swing arm bearings? My Beemers have a way to use a grease gun, looks like these must be removed and repacked.

Got the Yamaha tool for replacing the shims if a valve clearance check shows the need for it. My goal is to take it out this fall.

 

I recommend replacing all of the wheel bearings. They're CHEAP. Unless you managed to ONLY tap on the outer races, they need replacing anyway.

In regard to the swingarm bearings (the shafties have bearings, the 550s bushings) if you're going to go to all the trouble to take it apart, just replace them.