85 XJ700N, I can't get the forks apart

1985 XJ700N
Trying to replace teh fork seals, I have them off the bike, opened the top, out came the spacer and spring but nothing else. I tried the 5/8 socket backwards, it measures 19mm but not catching. I can't get the allen screw out of the bottom. What to do?

 

Re: I can't get the forks apart

I had to make up a tool consisting of a nut and bolt, a socket to fit the nut and two extension bars. The bolt head needs to be 19 millimeters across the flats. Screw the nut onto the bolt really tight. Then, clamp one of the extension bars in a vice with most of it pointing vertically upwards. Attach the second extension bar to the first. Place a socket to fit the nut on the upper end of the extension bars and then place the nut in the socket leaving the 19mm AF bolt uppermost. Now lower the fork tube over the whole thing and gently turn until the 19mm bolt engages with the fork. It is now possible to undo the screw in the end of the fork wihout the whole thing turning. If you don't have a 19mm bolt, three quarters of an inch is near enough.
Good luck.

 

Re: I can't get the forks apart

I did the 5/8 socket backwards and the end measures 19 mm but it doesnt bite or lockin.

 

Re: I can't get the forks apart

It may be different on your bike; the "generational commonality" was '80~'83; there simply weren't any '84 Yammies in the States and then the '85s came out.

Change the title of this thread. Change it to "85 XJ700N I can't get the forks apart."

We need someone with direct experience on the later bikes to chime in. In this case, I'm completely useless except to say the size at the bottom probably isn't 19mm. Just guessing, make something that gives you a 17mm end. (Yamaha's general M/O doesn't use even head/socket sizes until you get down to 14mm.)

 

This is the tool you need (sorry, freehand with a mouse is not my specialty):

One end is 19mm (3/4") and the other is 22mm (7/8") As you can see, you need to create a bolt head at the end that Robbie previously mentioned. The hex flats will fit into the piece you're trying to hold.

Now if you don't have the proper extensions to get to the 25" length, you'll never reach down into the tube far enough. The socket head (Allen head cap screw) at the bottom is 8mm (5/16").

If you can't create the tool to do the job, Chacal has them available.

Tony

 

a spark plug socket backwards and all the extentions in my box is what i used

 

Re: I can't get the forks apart

A 5/8 socket backwards is 19mm diameter and is round and smooth. The inside of the fork that you are trying to stop turning has a recessed hexagon similar to the head of an Allen Cap Screw. You need to simulate the way an Allen key fits into an Allen Cap Screw. The tip of the extended arrangement that you feed down the fork leg must have a male hexagon of a size that matches the recessed hexagon inside the fork. It could be 19mm A/F (that means 'Across the Flats') or 17mm A/F.

 

I would assume he meant a 5/8" spark plug socket with hex flats on the outside; most are effectively 19mm and make a perfect tool for this.

If the "hole" is indeed 19mm in those forks too, then you probably didn't have a long enough extension.

 

I used a 13/16- 21mm spark plug socket and it fit so I was ables to get it apart.

 

Take an old broom handle and taper the end a little. Put it down the tube and hit it with a hammer with a few good wacks until its seems stuck. Hold the broom handle while backing out the allen headed bolt. Its getto but it works every time.

 

Thanks all, I got them apart, all cleaned up and back together with new "All Ballz" fork seals and 10wt Maxim fork oil. I will reinstall on the bike tomorrow.

Next I tackle the dreaded carburetors. Gonna bust the rack and replace the throttle shaft seals. Lucky me I have a 2nd set of carbs to use as a reference if needed. Has anyone boiled the carbs to get them clean? Kinda like a crawfish boil without the crawfish or seasoning or corn or potatoes or butter, well you get the picture. Oh and the garlic, cant forget the garlic.

 

You may find the fork a tad "soft" when you start riding on it; if so, bump up to 15W fork oil.