Fork Disassembly Part II

I have disassembled one leg of the front forks about 90%. Still am unable to remove the socket head bolt that passes through the axle end of the fork. The bolt turns the inter tube assembly. The Yamaha Factory Manual said there is a tool to hold the inter assembly, the photo is not very clear. It looks like it is just a taper with a sharp edge on a long tee handle to bit into the inter assembly. it seem a little crude of a method? I have used a similar type tool to remove faucet seats.

 

1. It would help to know which XJ you have (add it to your signature) as there are a few threads here with more detailed pictures and procedures.

2. The special tool is dependent on which XJ you have, and can be substituted for with either a flipped sparkplug socket and several extensions, a fancy (custom made) nut welded to a steel rod, or a wooden broom handle.

 

Sorry
82 XJ650RJ Seca

 

this is the home made tool in haynes manual
its just a bolt and nut run through a 1/2 inck drive socket.
it is just to hold the damper rod ,toy turn the bolt . the bolt has lock tite on it and should be heated to soften the lock tite.
I have the rod Kmoe speaks of I will post the sizes of the nuts welded to it so you will know which 2 sizes you have to choose from.

 

• this tool can work too
• 
  
• One-piece tool that fits 17, 19, 22 and 24mm internal hex axles.
• 3/8" square drive on each end.

http://www.ebay.com/itm/Tusk-Hex-Ax...:g:4FgAAOSwWnFV8dbY&item=171927692434&vxp=mtr

 

Thank you.

 

my tool has 22mm and 19 mm nut welded onto each end (1 nut on ends)of a tube its abouit 2 fee long).
I bought it from our supporting member Chacal. it is a great tool but I had 3 sets of XJ fork tubes to rebuild and am expecting another XJ soon

remember to heat the allen head bolt in the bottom of the fork tube to soften locktite this is important

 

Got it apart, thanks to everyone who responded.
Used a 5/8 spark plug socket with a 3/4 inch hex end. The 3/4 in was a little to large to drop int the 12 point female. Being a very cheap plug socket and I own several of this size I filed the chrome off the 3/4 in hex. Dropped into the female 12 point. The 8mm socket head bolt came out with no effort.
I plan to file the plug socket a little more for a better fit and to cut a 8mm L hex key off to make the second side easier and for reassembly.
I have a box of modified tools that I have done over the years. Some day someone will look through the box and wonder what I was thinking.