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Removing front shock air hose union

Discussion in 'XJ Technical Chat' started by Core, Jun 5, 2016.

  1. Core

    Core Active Member

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    Hey guys, hoping someone can give me a tip to get the air hose union (Haynes workshop manual name) off of the front forks of a XJ900RL (1984)

    This part must come off before the individual fork legs can be removed.
    Here it is right under the top
    DSC_0684.JPG

    Closeup
    DSC_0683.JPG

    Ive disconnected the air hose but how to remove these sleaves
    Here show in the manual
    screengrab201606052206-002.jpg

    Can someone give me some pointers please?
    many thanks
     
  2. Polock

    Polock Well-Known Member

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    loosen all the pinch bolts, pull the forks down a little, right under and over the "air hose union" is a wire clip, pry it out of it's groove, slide everything off the top of the fork
     
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  3. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    ^ what he said.
    The hose was put on before the air collars were installed on the bike.
    There might not be a clip on the top of the collars, but there will be a rubber doughnut.
     
  4. Yardawg

    Yardawg Active Member

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    The wire clip is under the collars. They should just slide off as you pull the forks down. Mine did
     
  5. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    You might have to give the air collars a twist. The o-rings can harden and stick to the fork tubes. New o-rings are available from Chacal should you need them. They are a special size.
     
  6. Guestdawg

    Guestdawg Member

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    What's the reasoning for removing the air hose?

    Just seen it has to be removed to get individual fork leg off
     
  7. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    The air hose really doesn't have to come off at all unless it's leaking and needs to be replaced.
     
  8. Core

    Core Active Member

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    Many thanks again for all your help guys. The sleaves came off with no problem.

    I read in the manual that the air pressure of the this air union is between 0.0 bar and 0.4 bar (0.4 being the hardest setting)

    I am planning on dropping the front end and am wondering if it would be wise to simply leave the sleaves off.
    If the holes are blocked by the top clamp, or even if the holes are left open. What would be the result?
     
  9. Polock

    Polock Well-Known Member

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    the air acts like a progressive rate spring, even if there's zero pressure at rest they are sealed and there is pressure when the forks go down. If they were only partially sealed by the top clamp, the pressure of the down motion would push air out. in a series of bumps more air might get pushed out than could get back in and create a vacuum in them until the pressure equalized.
    i don't remember ever seeing vented forks.
    you might get sprayed with oil :)
     
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  10. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

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    The worst part about leaving the air holes open is when the fork oil shoots out.

    If you are going to slide the fork legs up in the clamps you can block the holes with epoxy. Clean them really good with carb cleaner, followed by alcohol. Use a length of masking tape as a backer on the inside of the tube. Fill the hole and wait for the epoxy to cure. Use a razor blade and finishing paper to make the epoxy flush with the surface of the fork leg.
    The air spring will be there without the air collars; it just won't be adjustable.

    At least one forum member sucessfully mounted the air collars above the top clamp. That might work for you if you plan on lowering the front that much.

    You could also just lower them by making spacers for the damper rods http://www.chopcult.com/forum/showthread.php?t=7330
    That does shorten the travel though.
     

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