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Fork Disassembly Problem

Discussion in 'XJ Technical Chat' started by LazyBeerNutz, Aug 25, 2008.

  1. LazyBeerNutz

    LazyBeerNutz Member

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    So in the process of pulling the forks apart to replace the seals you have to remove the top cap right? Well, mine is stuck. Stuck bad. Like I put it in a fork vice (courtesy of the local shop) and hit it with an impact gun stuck. Oh yeah and heated it up with a torch, then hit it again with the impact gun stuck. It's currently sitting in the garage with some penetrating oil in the top. I got one unstuck that way, but the other is being stubborn.

    Anyone have ideas on how to get it unstuck?

    Oh yeah and Chacal when you read this, I'm probably going to need new top caps (the threaded ones).
     
    LazyBeerNutz, Aug 25, 2008
    #1
  2. jswag5

    jswag5 Member

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    i had to put some serious torque to my caps to pop them loose. turn the fork upside down in a cup of rust-buster. just be careful if you have air assisted shock because those valve have been near impossible for me to find since i broke one, have a makeshift air valve in there now. Working in a refrigeration shop i brazed in a a/c access valve.
    i had a 6 foot pole on a breaker-bar and cranked on it.
     
    jswag5, Aug 25, 2008
    #2
  3. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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    CAP BOLTS-R-US!:


    HCP8292 OEM inner fork tube CAP BOLT, fits either side. Used on all XJ700 non-X and XJ900RK Seca models. Each:
    $ 25.00


    HCP8286 OEM inner fork tube CAP BOLT LOWER GASKET, fits either side. Used on all XJ700 non-X and XJ900RK Seca models. Each:
    $ 4.95

    HCP8286SET2 OEM inner fork tube CAP BOLT LOWER GASKETS, fits either side. Set of two:
    $ 5.50


    HCP8287 OEM inner fork tube rubber top CAP, fits either the left or right side tube of the following models: all XJ700 non-X models. Has the polished chrome metal decorative surface cap as original. Each:
    $ 8.00



    HCP9238 Aftermarket fork upper cap bolt REVERSE HEX SOCKET TOOL. This tool allows the easy removal and installation of the "inverted/reversed" hex-drive cap bolt used on the top of the inner fork tubes on all XJ650 Turbo, XJ700 non-X, and XJ900RK models.
    $ 12.95
     
    chacal, Aug 25, 2008
    #3

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