1981 XJ650 fork seals

No it would not be different with the heat gun. I suggested a heat gun simply because of the flammable nature of oil. Doing both together would be good though if you haven't tried that - heating the tube while pulling on the cap with a strap. Problem with the strap method is pulling at even a very slight angle not perpendicular to the tube is going to cause problems.

The slide hammer as K-moe suggested is still likely the best bet, as it would shock the cap, and also allow a bit of back and forth motion on the cap in case it is wedged at an angle. Using heat and the slide hammer together would also be a good idea. Also, if the cap is wedged or becomes wedged because it is not perpendicular to the tube could be corrected by a slight tapping motion with a brass punch around the outer circumference of the plug.

Patience is also good here, you mentioned earlier giving it another night of soaking, which is a good idea. Hopefully, you have the Kroil, which is highly recommended by the member on this site.

 

Well, nothing seems to be working. It hasn't moved in or out at all. I'm starting to lean towards just leaving it in and trying to flush it out as best as possible, renew the oil, and away we go. I can still put a new oil seal on etc. Just no new 'o-ring' on the cap bolt. Anyone think that would be a terrible idea?

 

Very terrible. The compressed cap is loading that fork differently than the other. Both forks should be set up equally. Imo since k-moe's tire/jack technique didn't work (which usually does) use his hammer jack suggestion. Replacing the too pitted to be re-used cap is a lot cheaper than having to replace a damaged fork.

Gary H.

 

Considering how pitted the other fork leg is, you'd be better off looking for replacement forks. I don't see an o-ring being able to seal properly without having the bore-worked.

 

That's ^ true too.

Gary H.

 

Yea, I figured as much so I've been looking around locally for replacement forks. I've found a couple forks from an XJ650 Maxim. Does anyone know if there are fitment issues? I essentially only need to replace the inner tube and top cap, everything else of mine is great. Are the length and diameter of the inner tube the same on the XJ650 Maxim and XJ650RJ Seca?

 

One source says they are both 36mm diameter, another says the Maxim has a 26mm air assisted telescopic fork.