Quick fork rebuild question

Is a fork rebuild on an 82 XJ650 a few hour process or is it a weekend job? This would be the first time I've done it and will follow along the write-up by Gamuru. I'm just trying to make a decision on when I want to do this. It looks like it wouldn't take long but figured I'd ask.

Thanks,
Stacy

 

My first rebuild, on a Honda VF1100C, took about 5 hours. My second rebuild, Yamaha XJ650, was only 3 hours. My last one, Suzuki VS1400, was just over two hours.

For me, there was a learning curve and building of confidence.

 

will you be taking them apart or just putting seals in?

 

Thanks Wink. Polock, I'll be doing what Gamuru's write-up shows. I would assume that would mean taking them apart if I'm understanding it right. I bought a basic fork rebuild kit from chacal so that's what all I'll be doing with them.

 

Set aside most of a day. Take your time. Do it right.

 

the first thing i do is drain the oil, then bounce the forks a bit(oil's going to squirt, be ready) let them drain while you jack up the front end.
sometimes those seals are really stuck in there.
those bushings/bearings they talk about would be good to put in, if your not, spin them 180 deg, they'll be worn on one side, you'll see what i mean

 

I would bet any mechanically able person with a good set of tools could do the job in under 8 hours their first time. Especially the 650's forks because they're pretty simple.

Be sure to use a torque wrench on the bolts which hold the forks into the triple clamps. I cracked my top one once because I tightened it too tight.

 

Remember to pull the Schrader valve cores before you start so there is no air pressure.

In the shop I try to schedule forks so I can start them draining the night before. That extra time to bleed out makes the job a little less messy. To do that you jack up the front, pull the wheel and valve cores, open the drain screws and go away until next morning.

 

Thanks for all the tips.

Polock, I don't see any bushing/bearings mentioned for my model (82 XJ650 Maxim). Am I missing something? Please explain.

 

check this out again, the posts by Ass.Fault.
http://xjbikes.com/Forums/viewtopic/t=8355.html
that's what i was talking about, maybe the 650's don't have them. best thing is drop chacal a pm and ask him. if he don't have 'em you don't need 'em

 

Oh, ok....I don't think those are on the 650. He said that he saw them on the 750 Seca. Thanks for the heads up though.

 

I haven't tried it myself, but a friend of mine had good results popping the seals out with extra air pressure into the air valves. I would imagine you would want to drain them as much as possible first to avoid a mess.

 

XJ650 Maxim only use a bushing in the top of lower (outer) fork tubes, and do not use the bushing at the bottom of the chrome (inner) fork tube (like the XJ750 Seca and some other models do).

 

chacal, is that bushing included in the basic rebuild kit I bought from you? I don't see a bushing labeled in the picture in the Haynes manual....is it something that is normally changed?

 

No, the bushings are not included in either of the fork rebuild kits (basic or performance) since they are:

a) very expensive
b) rarely need replacing, except on high-mileage or very neglected forks.

 

Ok, thanks.

 

like i said
"those bushings/bearings they talk about would be good to put in, if your not, spin them 180 deg, they'll be worn on one side, you'll see what i mean"

 

I'll take a look at them Polock....thanks.