MAJOR Front End Rebuild - Have I forgotten anything?

So I'm trying to make a parts/order list to rebuild my front end (calipers, MC, brake lines, front tubes, and triple tree connection area).

Obvious things to order (without disassembling anything yet) include:
* All rubber/seals as possible - The stuff IS 30 years old
* Hand Grips (already have)
* Front Control Cables (I think I have all of them - ie speedo, clutch, choke)
* MC Glass (done)
* MC rebuild kit (already have)
* Stainless Steel brake lines and bolts/washers (already have)
* Brake Pads (already have)
* Caliper Piston/Seals Kit (recommened for XJ750Js)
* Caliper Bracket Boots (4 total - They are rubber)
* All O-rings for air assist forks near handle bar connection
* Lower Forks Dust Seals
* Lower Forks Oil Seal (already have)
* Lower Forks Drain Screw O-Rings
* Front fork progressive springs
* Front Wheel bearings and oil seals

I know this is not a cheap list, but I'd rather not take my Fairing off 10 times this season. Also I'm going to be painting misc parts with Por15 paint that takes 7 days to cure. So the more I do in one MASS dis-assembly the better.

Without actually listing part numbers, have I forgotten anything major or typically worn out beyond reuse?

 

-Copper crush washer for the damper rod holding bolt
-Brake caliper o-rings if you plan on splitting the halves....they may or may not be included in the seal kit (there usually isn't a part # for them so you may have to hunt a little.)
-Fork oil
-Brake fluid

 

Steering head bearings-clean,inspect, repack with grease or replace.

 

I have no idea where that is...
Which sub page is it on for the fiche?
Fiches

Thanks for the reminder. I'm probably just gonna replace. I have a bit of wobble that in the past others suggested replacing the bearings.

 

I have no idea where that is...
Which sub page is it on for the fiche?
Fiches

It seals the allen bolt to bottom of the fork.... part #509-23158-LO-00

You should also consider replacing the damper rod seal on the inside, it goes by different names....'spindle taper' 'oil lock piece' 'oil seal'

what model do you have J or RJ?

 

+1...This may be all that's needed to eliminate your wobble, maybe a slight snug on the castellated nuts.

The bearings come out easy, the races....not so easy, total replacement can become a project.

 

I had the above listed part on my list of OEM part numbers. :wink:

Since I haven't taken anything apart yet, I didn't realize the 1W1-23173-L0-00 Taper Spindle was a "wear" item.

My list keeps getting bigger and bigger (just adding rubber parts and seals and obvious items to replace). Even if I can afford it in one purchase, the project is not going to be super quick to finish. *shrug*

BTW I have an '82 XJ750J Maxim.

P.S. It's a shame the OLD fiche images for my bike are so fuzzy and sometimes hard to see/read (even on a 27" PC Monitor). The service manual pictures are nice and clear, but not as complete or drawn exactly the same (some are combined or split up).

 

The Haynes manual claims I need 2 specialty tool and propane torch to redo the front forks... SIGH... Thought project would be easier than this...

 

[/quote]I had the above listed part on my list of OEM part numbers. :wink:

Since I haven't taken anything apart yet, I didn't realize the 1W1-23173-L0-00 Taper Spindle was a "wear" item.

My list keeps getting bigger and bigger (just adding rubber parts and seals and obvious items to replace). Even if I can afford it in one purchase, the project is not going to be super quick to finish. *shrug*

BTW I have an '82 XJ750J Maxim.

P.S. It's a shame the OLD fiche images for my bike are so fuzzy and sometimes hard to see/read (even on a 27" PC Monitor). The service manual pictures are nice and clear, but not as complete or drawn exactly the same (some are combined or split up).[/quote]

Sorry....I missed it.

The spindle taper is not a normal wear item but sometimes they are plastic and being 30 ys. old.....

Although my '85 XJ700X were aluminum (and in great shape) maybe someone on here has done an '82 XJ750J and knows if they are aluminum or plastic.

 

Well unless I don't want to ride at all this spring/summer my MAJOR overhaul is on hold yet again.

MANDATORY overtime (added 6th day of work) for the next 6-8-??? weeks. So I'll have little time or energy for major projects.

I'll probably start out smaller (and with a smaller shopping list) just doing the following:
* Rebuild/Paint Calipers (Since I have all other parts needed to redo front brake system)
* Inspect/Replace front/rear wheel bearings (they will be off anyways - I also have a new set of rear pads I was gonna throw on this year)
* Inspect/Clean/re-grease/tighten front steering bearing if I get a chance

Front forks with new springs will probably wait - I won't be doing much 2up riding this season apparently...
Upper triple tree area o-rings and stuff will wait until I tackle the forks.

I really did want to get my bike in tip top shape, especially with gas so expensive and wanting to ride to work daily... Hopefully nothing major breaks because I probably won't have the time/energy to fix it for a while... GRRRR

P.S. I'm working 2nd shift and don't have a garage so MAJOR projects are limited to my driveway and what I could have done over a normal weekend.

 

Save yourself some hassle trying to get it all done at once. Pick up another set of forks to rebuild, or use during rebuild. That way the bike will not be down for the process, and it is an easy afternoon to replace the forks.

Spare parts are always good to have around. Just in case!

Ghost

 

Something else you might need is degreaser....the bottoms of those forks probly have a bunch of dirt and filings packed in that you will want to flush.

Why not ride the bike this summer and do the front end work in the fall....the forks, wheel, etc. are small enough to be removed and brought inside if the weather sours. Just a thought.