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XJ 1982 Seca: fork seal replacement

Discussion in 'XJ Modifications' started by sjengg, Jun 26, 2013.

  1. sjengg

    sjengg New Member

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    Dear XJ fans,

    I'm trying to replace my fork seals.
    I dismantled the fork (air assisted-anti dive) just like the prescriptions in the manual.
    Every screw is loose, the circlips are loose, springs and damper rod are out, but I can't take the stansion apart from the lower fork. There's a metal on metal sound if I try to distract the stansion. I doesn't sound plausible that pulling harder would be the solution to this.
    Anyone got some tips?

    Thank you from The Hague, Holland!

    Jan Boerema
     

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    sjengg, Jun 26, 2013
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  2. ManBot13

    ManBot13 Well-Known Member

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    WHAT EVER YOU DO, DON'T SLAM THE INNER FORK DOWN!!! Now that you've removed the lower bolt, there are a set of wave-washers in the bottom that will get crushed to little bits if you do.

    The basic instructions is to use the inner fork as a slide hammer, and bash the bushing in the outer fork UP to drive the seal out.

    The way I did it last time (and some people gave me a hard time because it's messy) is to re-install the lower bolt, then fill the entire fork with oil (something you don't mind throwing away), installing the air valve and top cap, basically making the whole thing oil tight and hydrolocked. You drop that into a shop press (or make one out of a hydraulic jack and some 2x4's <- what I did) and using the hydraulic force to drive the fork seals out.

    I've done the first method, destroyed the wave washers, and I think even contorted the bushing (it did not want to come out). The second way, though messy, won't do any damage to any part of the fork.
     
    ManBot13, Jun 26, 2013
    #2
  3. sjengg

    sjengg New Member

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    Thank you for your quick response ManBot13....I already (luckily) noticed the parts in the lower fork, so I'll be careful with them.
    Okay, I'll try the inner fork sliding method.
    One question remains: the sound/feel when using the inner fork as a slide hammer is cloink! cloink!, steel on steel contact...is that okay? Is doesn't sound right, but if that's safe I'll try it again..but what steel hits what steel? I supposed that the entire oilseal would be made of 'rubber'?
    Thanks anyway, I'm looking forward to your answer.

    Greetings Jan Boerema
     
    sjengg, Jun 26, 2013
    #3
  4. k-moe

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

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    There is a steel washer under the oil seal.
     
    k-moe, Jun 26, 2013
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  5. ManBot13

    ManBot13 Well-Known Member

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    Again, that's the accepted method. The bushing that you are driving against the washer isn't a complete circle, and in my case, it jammed up under the washer, twisted and got stuck. Maybe I did something wrong or was just unlucky but when it got stuck, I had to slam the inner fork downward to get it un-stuck and try again. That's what destroyed the wave washers.

    Here's the best how-to thread for 750 Seca forks:

    http://xjbikes.com/Forums/viewtopic/t=1 ... build.html
     
    ManBot13, Jun 26, 2013
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