Fork Disassembly Help

Replacing the fork seals and oil on my 82 XJ750 SECA. I can't seem to get the upper tube out! I have removed the damper rod bolt and slid the damper rod out. It seems like I should be removing a retaining clip to further remove the tube, but I can't get the seal out to access the clip except nibbling away piece by little piece. Am I missing a step?



Also, there is a nylon ring around the top of the damper rod. (Far left center of image). It is cracked. Is this normal?

 

You have to remove the dust seal under the seal is a snap ring that has to be removed and a large washer under snap ring . Once removed grip tube and lower tube slide it back and forth with some force it should pull apart . Relax looked at pictures your dampner rod looks fine. To get out dudt seal you take a flat blade screw driver and pry it out it will NOT be reused so don't worry if you destroy it. I just rebuilt mine took a couple of hours , but I've rebuilt forks before these are easy to rebuild. Go to the xj4ever overload hour one of our member has a nicewrite up on rebuilding Seca forks

 

I heated the seal up and that shortened the process considerably. Be careful not to scratch anything. I put a rag under the screwdriver before I pryed it out.

 

Doing the 750 Seca's Forks.. (Rebuild.. now a HOW TO!)

I really hope that your pulling on the fork leg with the circlip in hasn't damaged both the upper and lower bushings. You have already dislodged the lower bushing from the upper fork leg.

 

Looking at the picture a little bit closer, I'm wondering what happened to the thin spring-washers that go between the oil lock and the damper rod.

 

Thank you all!
Think I got it. I was being too timid about getting the dust seals out. I mistook the metal ring inside of the dust seal as part of the lower tube and was being extra careful not to scratch it up. Once I got under that, it pried right out. A little heat from from a heat gun probably helped as well.

I hope not too! What do you think?


Bad news, when I purchased the fork seals from a local motorcycle shop out of convenience, it looks like I only got the dust seals and not the inner oil seals. Convenience not so convenient.

 

They were still in the lower tube. I was careful not to let things slam the bottom. The semi-folded spring washer still looks to be in good shape.

 

The bushings look good. As long as they aren't deformed, and the coating hasn't worn through to copper they're serviceable.

 

Sounds like it's time to chew out your parts guy... then use Len@ Xj4ever instead.
Right parts, less fuss driving to your local dealer and probably get there a day or two sooner.
Unlike most parts ppl today I think Len has turned a wrench or two and will get you all the things you need to complete the job

 

Len at xj4ever his parts are great...yes might be more than you might pay on eBay...BUT they will be the correct parts . When I did my forks I put new wheel bearings and seals ordered from xj4ever these came with directions even . As an old saying goes buy the best cry once.... your further ahead buying from len than someone that you don't know where the part might fit or not

 

XJ4ever.com is my first and only stop.

 

Yes, I know Len is THE source. Just thought I would save time, a little $, I happened to be driving by the motorcycle store, and I wanted to check out some other gear. Turns out the seals were correct, just looked slightly different than what was in there, BUT, I don't have dust seals, and neither does the motorcycle shop; they said I had to go to the dealer. I will be getting in touch with Len at XJ4ever. Meanwhile, I went ahead and got both forks completed.

First one took me all day, because I didn't know what the hell I was doing. This is my first bike, but I've done automotive stuff before. When I got to the second one, I thought, "piece of cake, one hour tops." UNTIL I ran into a very stubborn bottom bolt that goes into the damper rod and it was starting to round out. I didn't want to force it. An hour and a half later, maybe it was two? I got it to break free.

So, my forks are rebuilt, with the exception of the dust seals. That shouldn't take too long once they arrive. Slip them on and tap into place. Then I can reinstall the forks and begin to button things up.

I really appreciate everyone's help here!

 

The next time you have to tear forks down, invest in a broom handle. Use it to hold the damper rod still while you remove the damper rod bolt (sick it down the fork leg and push).

Did you disassemble and clean the anti-dive units?

 

Funny, I accidentally? found a wooden dowel laying around for that exact purpose of holding the damper rod. Was surprised it held the damper rod from turning as well as it did. It was smaller than a broom handle, but wedged inside of the damper rod tightly. Used a vise grip on the protruding end to keep it from turning while I loosened/ tightened the bottom bolt. It wasn't the turning so much of a problem as it was stripping out the Allen bolt from the torque. If I did that, I would have been in quite the predicament of disassembling the forks.

Yes, in fact, I did tear down and clean the anti-dive unit components. They didn't look too bad; outside of the sludgy oil. Cleaned the parts up with brake cleaner and mineral spirits. As long as I have something torn down, may as well clean it up before reassembly.

 

I still prefer the , pop the dust seal, remove oil seal retaining clip, loosen top cap if it's a screw in type, let air out of forks if it has them, clamp upper tube in wood jaw bench vice , place oil drain pan under fork, hit the retaining bolt with air gun and your done. Won't spin with spring pressure holding it. And impact gun breaks the thread lock present on most forks
Always done it this way never had a problem

 

Next time. Haha, hope there is a next time as it will be a ways down the road. Don't have an air impact gun. Maybe should think about getting one.? I did check with my neighbor that has one, but we were concerned since the bolt was already rounding out, the air impact gun would finish rounding it out then we might be drilling it out. Would one of those battery operated impact guns work too?

 

A battery powered impact is all I needed.