1982 XJ550H fork seal repair

I am attempting to change out my fork seals. I have removed the forks but I am stuck on getting the top ring out. I have drained the oil and managed to break loose the bottom hex bolt.

I can hear the spring inside turning. However, the plug at the top of the forks I cannot get out. Any suggestions?

The service manual says to leave the forks on the bike and depress the forks by pushing down on the bike. this will release the pressure on that top spring and allow the plug to be removed. Is this true?

Thanks,
Jeff

 

Jeff,

The top plug needs to be depressed.
While this plug is being pushed down you will see a retaining circlip

The trick is... the circlip must be removed WHILE holding the plug in.
A small electrical flat head screw driver works well to remove the circlip. Even using two screw drivers works well if you have the ability to multi-task.

Me...I used a 1/2 socket wrench with a 9" extention. I placed this tool against my sholder to depress the plug. That left me with two free hands to manuver the two small screwdrivers

 

Sometimes the top fork clamp is overtighten top not alowing the cap to be pushed down. Loosen the top clamp see if this helps Been there did that.

 

Thanks a lot guys,
I will try that tonight and will respond with how it goes.

Take Care
-Jeff

 

It worked perfect. Thanks again.
Now all I need is some good weather.

Best of Luck,
Jeff