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Fear of the circlip

Discussion in 'XJ Technical Chat' started by Madone1, Jun 27, 2008.

  1. Madone1

    Madone1 Member

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    Okay, the time has come to replace my fork seals, and I have read pretty much every "How-To" on this site. It sounds like it is a job that is not difficult if you are patient and have the right tools. My only real concern is with the circlip. Just how difficult is it to get that thing out? I'm planning on using a barclamp to compress the cap, like I have seen in the How-To, and then use a pick to try to get it out. I really hate the thought of that little piece of metal preventing me from doing this job myself. My Yamaha dealer wants $279 to do the job, with the forks off the bike. A local repair shop will do it for $150 with the forks off the bike. Am I wrong in thinking I can do it for under $50 if I do it myself?

    Help me before I go crazy!
     
    Madone1, Jun 27, 2008
    #1
  2. RickCoMatic

    RickCoMatic Well-Known Member

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    Don't be afraid!
    Save yourself all that money.

    Clean the whole area where the Circlip lives.
    Pry out the Circlip.
    The Fork is Spring Loaded ... be prepared!

    The Inner Tube is not released until the Damper (inside) is undone from the very bottom of the Fork.
    There's a Allen Bolt holding the Damper in.

    You need to fashion a tool to insert down the inner tube to hold the Damper from rotating while the Fastener at the bottom of the Fork is undone.

    A Spark Plug Socket mounted backward on a long extension will do the trick.
     
    RickCoMatic, Jun 27, 2008
    #2
  3. Polock

    Polock Well-Known Member

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    if you get the seals and fork oil from a dealer, your getting close to 40
    that circlip is no match for your skill and determination :)
     
    Polock, Jun 27, 2008
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  4. brtsvg

    brtsvg Member

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    I just did this for the first time on my XJ650 recently, by myself no less although an assistent would have made things easier. This was no big deal or difficult to accomplish. The circlip is easy to remove it you have a dental pick tool (or something equivalent with a sharp point). It may be slightly more difficult to dislodge the clip from the groove with a screwdriver. Give it a try !
     
    brtsvg, Jun 27, 2008
    #4
  5. Madone1

    Madone1 Member

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    Okay,you guys have convinced me to give it a whirl, so I priced the seals at my Yamaha Dealer. $40 for both oil seals. Good price/Bad Price? Should I get the Yamaha seals or will the aftermarket seals I can get for half the price be okay?
     
    Madone1, Jun 30, 2008
    #5

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