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85 XJ900 FORK SEAL TRANSPLANT

Discussion in 'XJ Technical Chat' started by wizard, Mar 22, 2011.

  1. wizard

    wizard Active Member

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    85 XJ900 FORK SEAL TRANSPLANT.
    Jack the front of the bike.
    Remove the brake callipers & tie up out of the way.
    Unscrew the speedo cable.
    Remove the bolts at the bottom of the forks.
    Remove the axel bolt, note how the speedo drive fits into the fork leg & the orientation of the spacer on the other side.
    Remove wheel.
    Remove fender & hose clips.
    Remove fork brace.
    Remove caps at top of the fork legs.
    Slacken the 2 top bolts clamping the fork legs.
    Using a 10mm hex bolt with 2 lock nuts, loosen the top screwed plugs.
    Loosen the 4 lower clamp bolts & slide out the fork legs (if they are tight, tap in small screwdrivers to open the clamps)
    Fully remove the plugs & springs, invert & drain the oil.
    Remove the dust caps & replace if cracked (ease them out gently with a knife blade)
    Flick out the spring clips & remove washer below.
    Hold the damper rod with a suitable tool (I use a 200mm square box section with the end dented to form a star) & unscrew the allen cap screw at the bottom of the leg (don’t loose the copper washer)
    Remove the damper rod, rebound spring & bush.
    With the calliper flange held in ‘soft’ jaws in the vice, pull the inner tube sharply outwards so it contacts with the back of the seal, it might take a few hard jerks to release the old seal.
    Clean everything ready to fit the new seals.
    A good opportunity to do some polishing.
    Drop the damper rod, rebound spring & bush, in the proper order & bolt it up. Torque 17 ft lb.
    Slide on the thin washer, then the new seal, using the lubricant supplied, be sure the seal is square to the fork leg, tap into place using a suitable diameter length of plastic plumbing pipe, add the larger washer & spring clip.
    Replace the dust caps.
    If you don’t want to remove the handlebars, re-fit the main springs, add the fork oil,
    5 wt, 276 cm 3 to each leg & re-fit the plugs.
    Slide the tubes back into the clamps & tighten the bolts, torque 17 ft lb.
    Replace the fork brace & fender.
    Lightly grease the axel & replace the wheel, temporally tighten the pinch bolts before tightening the axel, torque 50 ft lb, then tighten the pinch bolts to 14 ft lb.
    Replace the callipers, torque 35 ft lb.
    Re-fix the speedo cable.
     
  2. adrian1

    adrian1 Active Member

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    I had a devil of job driving those seals home! I presume you used a split pipe with a hose clamp? There's just so little room to get a good swing to bang on the pvc pipe! What does the proper tool look like? I assume its some kind of a sliding hammer arrangement?
     
  3. Polock

    Polock Well-Known Member

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    A longer pipe
     

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