Fork seals?

Need to replace the seals on my '82 650. Before buying from bikebandit.com I'd like to make sure I've got everything. From the fiche it looks like I'll need 2 each of the oil seals, oil seal clips, and dust seals. Did I forget anything?

Thanks
Dean

 

You should also get the spring seat o-rings and new clips for the top of the fork.

Don't forget a liter or quart of 10w fork oil.

 

More fork tube parts than you can shake a stick at...........!:



FRONT SUSPENSION:


FORK TUBE PARTS:


Your front suspension is called on to do a lot of different tasks, sometimes all at the same time: steering and braking are the two most critical ones that come to mind. Thus the proper operation and integrity of your front forks, and all their parts and pieces, is vital to the proper operation, handling, and safety of your bike.

Although your front forks are pretty simple devices....a spring, inside a fluid-filled tube, that serves to soak up road imperfections while maintaining positive-yet-smooth road feel and control....there are quite a few items that need attention and periodic replacement in order to get the proper lifetime and performance out of your system.

We offer a variety of OEM and aftermarket products and tools needed to properly maintain and service your forks and keep them firmly planted on the road beneath you.

While many people may simply need to replace the Oil Seal, Seal Clip, and the Dust Boot (sometimes called a "wiper"), we also recommend that whenever you have your forks apart, that you also replace the upper cap bolt Circlip or Snap Ring, the cap bolt O-Ring or Gasket, the fork oil drain screw Gasket, the damper rod retaining bolt Seal, and, on air-fork-equipped models, the air valve o-rings.

Replacing these items now, while the forks are apart, can help prevent leaks and problems from developing down the road.

On high-mileage bikes, you should also replace the metal slider bushings, taper spindles, and other items.

All models usually require the use of a damper rod Retaining Tool to hold the damper rod in place while the lower damper rod retaining screw (in the bottom of the lower fork tube) is being loosened or tighten; otherwise, the damper rod will spin and freely and make removal and installation difficult if not impossible.

While the basic servicing and rebuilding of your forks is not a specialized skill, it can be somewhat confusing and daunting to people who have never performed such a task before. Since the procedures vary (sometimes greatly) between the different model bikes, we can give no real instructions or recommendations besides this: refer to your factory or aftermarket service manual for the proper procedures and techniques, and if you don't already have such a manual, please purchase one!

The general layout of your forks (some models have more or less pieces than others), from the very top of the INNER (chrome) tube moving downwards, is as follows. Note that the items underlined are the ones that we strongly recommend replacing during a fork rebuild or seal replacement procedure.

- Top Cap (usually plastic)
- Circlip or Snap Ring or Stopper Ring
- Cap Bolt
- O-Ring for cap bolt
- Spacer (if used)
- Upper Spring Seat (if used)
- Fork Spring
- Damper Rod
- Lower Rebound Spring (if used)

The following items may need replacing on high-mileage bikes:

- Taper Spindle
- Metal Slide Bushing #2, a split-ring bushing on the bottom of the chrome tube.


Air-assisted front forks (1982-3 XJ650 Maxim and Turbo, all XJ750, XJ900RK, and XJ1100 models) also included the following parts. Note that the items underlined are the ones that we strongly recommend replacing during a fork rebuild or seal replacement procedure.

- Gasket (XJ750 Seca)
- Air joint upper and lower O-rings (upper o-rings only on XJ750 Seca)
- Air joints
- Air joint schrader valve (connected systems) or valves (individually
aired tubes) O-rings
- Air joint schrader valves and caps.
- Some models had an air hose that tied together the two forks (XJ650 Turbo, 1982 XJ750 Maxim, XJ900RK, and XJ1100) while the 1982-83 XJ650 Maxims, the 1983 XJ750 Maxim and Midnight Maxims, and all XJ750 Seca models used individually aired fork tubes.
- Piston Ring (XJ750 Seca, XJ1100)
- Gasket

Additionally, all XJ650 and XJ750 Midnight Maxim models, and XJ1100 models, had upper tube covers, their related guides and associated gaskets.


The LOWER fork tube is populated as follows. Note that the items underlined are the ones that we strongly recommend replacing during a fork rebuild or seal replacement procedure.

- Dust boot
- Oil Seal Clip
- Oil seal Washer (XJ750 Seca, XJ900)
- Oil Seal
- Oil seal Spacer (XJ750 Seca, XJ1100)
- Oil Lock Valve Assembly (XJ750 Seca)
- Fluid drain plug and gasket
- Damper rod retaining bolt and gasket
- Fork Oil


The following item may need replacing on high-mileage or poorly-maintained bikes:

- Metal Slide Bushing #1, a split-ring metal bushing near the top of the lower tube, just below the oil seal.



UPPER (INNER) FORK TUBES AND PARTS:


Chrome Inner For Tubes:

ift3) Reproduction inner (chrome) FORK TUBE, exactly replaces bent or rusted and pitted original tubes. Beautiful hard-chrome plating will last as long as original. You should always check your fork tubes with a known accurate straight-edge rule before beginning any inner or lower fork rebuild efforts, as a bent inner tube will quickly wear out new seals, as well as creating an unsafe riding condition.

All fork tubes are precision made from centerless ground, cold-rolled steel tubing, and are then machined to proper tolerances and specifications as original. All inner tubes will fit either the left or right side. Stock length tubes are listed below. Shorter or longer length tubes are available by special order, but are non-returnable or refundable, and must be inquired about directly with us specifying the length desired.


NOTE: due to the size and weight of these items, any discounted shipping offers do not apply to these inner fork tubes.


HCP8522 Aftermarket chrome INNER FORK TUBE, fits left or right side, for all XJ550 Maxim models, each:
$ 139.95

HCP8522SET2 Aftermarket chrome INNER FORK TUBES, set of 2:
$ 259.95



HCP8523 Aftermarket chrome INNER FORK TUBE, fits left or right side, for all 1981 XJ550 Seca models, each:
$ 139.95

HCP8523SET2 Aftermarket chrome INNER FORK TUBES, set of 2:
$ 259.95



HCP8524 Aftermarket chrome INNER FORK TUBE, fits left or right side, for all 1982-83 XJ550 Seca models, each:
$ 139.95

HCP8524SET2 Aftermarket chrome INNER FORK TUBES, set of 2:
$ 259.95



HCP8525 Aftermarket chrome INNER FORK TUBE, fits left or right side, for all XJ650 Maxim and Midnight Maxim models, each:
$ 134.95

HCP8525SET2 Aftermarket chrome INNER FORK TUBES, set of 2:
$ 239.95




HCP8526 Aftermarket chrome INNER FORK TUBE, fits left or right side, for all 1982 XJ650 Turbo models, each:
$ 139.95

HCP8526SET2 Aftermarket chrome INNER FORK TUBES, set of 2:
$ 249.95


HCP8527 Aftermarket chrome INNER FORK TUBE, fits left or right side, for all 1983 XJ650 Turbo models, each:
$ 139.95

HCP85276SET2 Aftermarket chrome INNER FORK TUBES, set of 2:
$ 249.95



HCP8528 Aftermarket chrome INNER FORK TUBE, fits left or right side, for all 1982 XJ650RJ Seca models, each:
$ 139.95

HCP85288SET2 Aftermarket chrome INNER FORK TUBES, set of 2:
$ 249.95




HCP8529 Aftermarket chrome INNER FORK TUBE, fits left or right side, for all XJ700 non-X models, each:
$ 139.95

HCP8529SET2 Aftermarket chrome INNER FORK TUBES, set of 2:
$ 249.95



HCP8530 Aftermarket chrome INNER FORK TUBE, fits left or right side, for all XJ700-X models, each:
$ 139.95

HCP8530SET2 Aftermarket chrome INNER FORK TUBES, set of 2:
$ 249.95





HCP8531 Aftermarket chrome INNER FORK TUBE, fits left or right side, for all 1982 XJ750 models, each:
$ 139.95

HCP8531SET2 Aftermarket chrome INNER FORK TUBES, set of 2:
$ 249.95



HCP8532 Aftermarket chrome INNER FORK TUBE, fits left or right side, for all 1983 XJ750 Maxim and Midnight Maxim models, each:
$ 139.95

HCP8532SET2 Aftermarket chrome INNER FORK TUBES, set of 2:
$ 249.95




HCP8533 Aftermarket chrome INNER FORK TUBE, fits left or right side, for all XJ750 Seca models, each:
$ 134.95

HCP8533SET2 Aftermarket chrome INNER FORK TUBES, set of 2:
$ 299.95




HCP8534 Aftermarket chrome INNER FORK TUBE, fits left or right side, for all XJ900RK models, each:
$ 139.95

HCP8534SET2 Aftermarket chrome INNER FORK TUBES, set of 2:
$ 249.95




HCP8535 Aftermarket chrome INNER FORK TUBE, fits left or right side, for all XJ1100 models, each:
$ 139.95

HCP8535SET2 Aftermarket chrome INNER FORK TUBES, set of 2:
$ 249.95




Inner Tube Top Cover/Cap:

HCP8252 OEM inner fork tube black rubber top CAP, fits either the left or right side tube of the following models: XJ550 all, 1980-81 XJ650 Maxim and Midnight Maxim, the 1982 XJ650RJ Seca, and 1981 XJ750 Seca models. Each:
$ 6.75


HCP8254 OEM inner fork tube black plastic top CAP, fits either the left or right side tube of the following models: 1982-83 XJ650 Maxim and Midnight Maxim, and the 1983 XJ750 Maxim and Midnight Maxim. Has the words AIR ADJUSTABLE cast into as original. Each:
$ 11.00


HCP8289 OEM inner fork tube black rubber top CAP, fits either the left or right side tube of the following models: 1982-83 XJ650 Turbo and the 1983 XJ900RK Seca models. NOTE: you can substitute the HCP8287 top cap in place of this one for a upgraded appearance! Each:
$ 9.95


HCP8287 OEM inner fork tube rubber top CAP, fits either the left or right side tube of the following models: all XJ700 non-X models. Has the polished chrome metal decorative surface cap as original. Each:
$ 8.00


HCP8291 OEM inner fork tube top black rubber CAP, fits either the left or right side tube of the following models: all 1982-83 XJ750 Seca models. Each:
$ 11.25



Inner Fork Tube Cap Bolt Circlip, Snap Ring, or Stopper Ring:


These rings, located at the very top of the chrome legs, underneath the top Cap/Cover, are what hold all the rest of the internal goodies in. They are usually pretty corroded after years of inattention, and it is recommended that they be replaced during any fork renewal process. Be careful when removing these items, they are under spring pressure!

HCP2323 OEM inner fork tube top cap bolt CIRCLIP, fits either the left or right side tube of the following models: all XJ550 models, XJ650 Maxim, Midnight Maxim, and Seca (RJ) models, and 1981 XJ750 Seca models. Each:
$ 6.00

HCP2323SET2 OEM inner fork tube top cap bolt CIRCLIPS, set of two:
$ 10.00



HCP8296 OEM inner fork tube top cap bolt STOPPER RING, fits either the left or right side tube of the following models: all 1982-83 XJ750 Seca models. Each:
$ 7.50




Inner Fork Tube Cap Bolts and Related:

This is the rather solid upper "plug" that retains the innards of the fork tube (the spring sits just below it). Some models may incorporate an o-ring onto this cap bolt; other use a gasket below it. Although these cap "bolts" normally don't wear out, their corresponding o-rings or gaskets should always be replaced. Some models with air-adjustable forks have the air valve threaded into this cap bolt, and the o-ring around that air valve should also be replaced during a fork service or rebuild.


HCP8255 OEM inner fork tube CAP BOLT, fits either side. Used on all XJ550 models, 1980-81 XJ650 Maxim and Midnight Maxim, and 1982 XJ650RJ Seca models. Each:
$ 19.95

HCP9882 Aftermarket inner fork tube CAP BOLT, fits either side. Used on all 1982-83 XJ650 Maxim models with air-assisted forks. These cap bolts have the drilled and threaded central hole where the HCP8274 air valve screws in (air valve is NOT included with the cap bolt). Each:
$ 27.95


HCP8294 OEM inner fork tube CAP BOLT, fits either side. Used on all XJ650 Turbo models. Each:
$ 33.00


HCP8292 OEM inner fork tube CAP BOLT, fits either side. Used on all XJ700 non-X and XJ900RK Seca models. Each:
$ 25.00



HCP2324 OEM inner fork tube CAP BOLT O-RING, fits either side. Used on all XJ550 models, XJ650 Maxim and Midnight Maxim, and 1982 XJ650RJ Seca models. Each:
$ 4.00

HCP2324SET2 OEM inner fork tube CAP BOLT O-RINGS, fits either side. Set of two:
$ 7.00




HCP8242 OEM inner fork tube CAP BOLT UPPER GASKET, fits either side. Used on all XJ650 Midnight Maxim and XJ750 Midnight Maxim models. Each:
$ 4.00

HCP8242SET2 OEM inner fork tube CAP BOLT UPPER GASKETS, fits either side. Set of two:
$ 7.00



HCP8241 OEM inner fork tube CAP BOLT LOWER GASKET, fits either side. Used on all XJ650 Turbo and XJ750 Maxim and Midnight Maxim models. Each:
$ 6.95

HCP8241SET2 OEM inner fork tube CAP BOLT LOWER GASKETS, fits either side. Set of two:
$ 12.95



HCP8248 OEM inner fork tube CAP BOLT LOWER GASKET, fits either side. Used on all XJ750 Seca models. Each:
$ 1.00

HCP8248SET2 OEM inner fork tube CAP BOLT LOWER GASKETS, fits either side. Set of two:
$ 1.95



HCP8286 OEM inner fork tube CAP BOLT LOWER GASKET, fits either side. Used on all XJ700 non-X and XJ900RK Seca models. Each:
$ 5.95

HCP8286SET2 OEM inner fork tube CAP BOLT LOWER GASKETS, fits either side. Set of two:
$ 9.50



HCP8299 OEM inner fork tube CAP BOLT LOWER GASKET, fits either side. Used on all XJ1100 models. Each:
$ 8.00

HCP8299SET2 OEM inner fork tube CAP BOLT LOWER GASKETS, fits either side. Set of two:
$ 14.95



Inner Tube Fork Springs:

Top-quality aftermarket progressively wound FRONT FORK COIL SPRINGS don't just "restore" the performance to your front forks, they actually improve it over the original equipment. Spring and suspension technology has come a long way in the 30 years since the XJ model bikes were designed and built, and our line of Progressive Suspension front coil springs will not only get rid of the sags and "mush" in your front end, but will give your bike a crisper, more controllable and predictable ride and handling quality due to their superior design, engineering, and manufacturing.

One pair of front springs does both front forks. Please note that some models will require the use, re-use, modification of the original, or the fabrication of the front spring spacers (and some models do not require the use of spacers at all).

NOTE: the more tightly coiled area of progressive springs (whether original or aftermarket) should be towards the TOP of the fork tobe.


HCP9433 Aftermarket front suspension COIL SPRINGS, one pair does both forks. For all XJ550 Maxim models. Front spring spacers are not included with these springs, and must be fabricated and sized properly when replacing stock springs.
$ 72.95


HCP9434 Aftermarket front suspension COIL SPRINGS, one pair does both forks. For all XJ550 Seca models. Front spring spacers are not required with these springs.
$ 72.95


HCP9436 Aftermarket front suspension COIL SPRINGS, one pair does both forks. For all XJ650 models. When using these springs with XJ650 Maxim, Midnight Maxim, or XJ650RJ Seca models, the stock front spring spacers will need to be shortened to fit (a hacksaw works well for accomplishing this task). When using these springs on XJ650 Turbo models, front spring spacers are not included and must be fabricated and sized properly when replacing stock springs.
$ 69.95


HCP9437 Aftermarket front suspension COIL SPRINGS, one pair does both forks. For all XJ700 models. Your original front spring spacers are required to be re-used with these springs.
$ 72.95


HCP9435 Aftermarket front suspension COIL SPRINGS, one pair does both forks. For all XJ750 Maxim and Midnight Maxim models. Your original front spring spacers are required to be re-used with these springs.
$ 69.95


HCP9438 Aftermarket front suspension COIL SPRINGS, one pair does both forks. For all XJ750 Seca models. Front spring spacers are required to be used with these springs and are included with this kit.
$ 74.95


HCP9439 Aftermarket front suspension COIL SPRINGS, one pair does both forks. For all XJ900RK and XJ1100 models. No spring spacer is needed when using these springs on the XJ900RK models. For use on XJ1100 models, front spring spacers are required but are not included, and must be fabricated and sized properly when replacing stock springs.
$ 72.95


Inner Fork Tube Spring Spacers and Spring Seats:


HCP8284 OEM inner fork tube SPRING SPACER TUBE, fits either side. Used on all 1982-83 XJ650 Maxim and 1983 XJ750 Maxim and Midnight Maxim models. Each:
$ 6.00

HCP8303 OEM inner fork tube SPRING SPACER TUBE, fits either side. Used on all XJ650 Turbo and 1982 XJ750 Maxim models. Each:
$ 9.95

HCP8302 OEM inner fork tube SPRING SPACER TUBE, fits either side. Used on all 1985 XJ700 non-X and all 1986 XJ700 models. Each:
$ 9.95



HCP8239 OEM inner fork tube SPRING SEAT, fits either side. Used on all 1982-83 XJ650 Maxim, 1982 XJ650 Turbo, and all XJ750 Maxim and Midnight Maxim models. Each:
$ 6.50

HCP8280 OEM inner fork tube SPRING SEAT, fits either side. Used on all XJ700 models. Each:
$ 10.00



HCP8246 OEM inner fork tube PISTON RING, fits either side. Used on all XJ750 Seca and XJ1100 models. Each:
$ 9.95



HCP8344 OEM inner fork tube VALVE SPRING, fits either side. Used on all XJ900RK Seca. Use 2 per tube, each:
$ 6.95



Inner Tube Metal Slider Bushings:

These split-ring bushings fit over into a recess at the bottom of the inner chrome tube, and along with the lower tube slider bushing, serves as a both a tube guide and absorbs the majority of the side loading of the inner tube as it passes through the lower tube. If the fork oil hasn't been changed regularly, grit and moisture in the oil eventually wear down these slides, and thus require their replacement.

Unfortunately, these slider bushings are only available for a limited number of models, For those models that need sliders, but for which there are none available, there is a solution:

The inner (upper or chrome tube) Slider Bushings is the most critical of the two; it's the workhorse and the one that takes the most loads. It is a split-ring bushings that fits into a machined recess on the bottom of the inner (chrome) fork tube, way down at the bottom of it. This slide bushings moves around as the forks compress, and if it's worn, it will cause the handlebars to vibrate and cause rider fatigue on longer trips.

You can test the condition of the lower slide bushing by installing it (or leaving it installed) on the bottom of the inner tube, lubricating it with fork oil, and moving the chrome inner tube up-and-down within the lower fork tube housing. It should move freely and neither bind nor have any real free play or slop throughout its travel. If it does have slop, and if a replacement lower slide bushing is not available for your bike, you can possibly extend the life of this bushing by using a piece of plasti-gauge bearing-checking material as a shim behind the slide bearing (in-between the chrome tube and the inside of the bushing shell).



HCP8481 OEM inner fork tube METAL SLIDER BUSHING, fits either left or right tube on the following models: all XJ750 Seca and XJ1100 models. One slider does one tube. Each:
$ 24.00

HCP8481SET2 OEM inner fork tube METAL SLIDER BUSHINGS, set of 2:
$ 44.00


NOTE: Inner slider bushings for all XJ700 models are available, but only within the HCP1715 fork tube rebuild kit listed further below.




INNER FORK TUBE AIR SYSTEM PARTS:

Air Joint O-Rings:


HCP8238 OEM inner fork tube air joint O-RING, fits either left or right air joint on the following models: XJ650 Turbo and 1982 XJ750 Maxim models. Uses 2 o-rings (above and below each air joint) per tube. Each:
$ 9.00

HCP8238SET2 OEM inner fork tube air joint O-RINGS, fits either left or right air joint on the following models: XJ650 Turbo and 1982 XJ750 Maxim models. Uses 2 o-rings (above and below each air joint) per tube. Pair:
$ 17.00

HCP8238SET4 OEM inner fork tube air joint O-RINGS, fits either left or right air joint on the following models: XJ650 Turbo and 1982 XJ750 Maxim models. Uses 2 o-rings (above and below each air joint) per tube. Set of 4:
$ 32.00



HCP8279 OEM inner fork tube air joint O-RING, fits either left or right air joint on the following models: XJ750 Seca models. Uses 1 o-ring per tube. Each:
$ 8.00

HCP8279SET2 OEM inner fork tube air joint O-RINGS, fits either left or right air joint on the following models: XJ750 Seca models. Uses 1 o-ring per tube. Set of 2:
$ 14.95



HCP8341 OEM inner fork tube air joint O-RING, fits either left or right air joint on the following models: XJ900RK Seca models. Uses 2 o-rings (above and below each air joint) per tube. Each:
$ 7.50

HCP8341SET2 OEM inner fork tube air joint O-RINGS, fits either left or right air joint on the following models: XJ900RK Seca models. Uses 2 o-rings (above and below each air joint) per tube. Pair:
$ 13.00

HCP8341SET4 OEM inner fork tube air joint O-RINGS, fits either left or right air joint on the following models: XJ900RK Seca models. Uses 2 o-rings (above and below each air joint) per tube. Set of 4:
$ 24.00


Air Inflation Valves and O-Rings:


HCP8274 OEM inner fork tube air joint AIR VALVE, with cap, fits the following models: 1982-83 XJ650 Maxim (use 1 per tube), XJ650 Turbo models (use 1 per bike), XJ750 Maxim and Midnight Maxim models (use 1 per bike), and XJ900RK Seca models (use 1 per bike). Each:
$ 17.00



HCP2322 OEM inner fork tube air joint air valve and air hose O-RING, fits the following models: 1982-83 XJ650 Maxim (use 1 per tube), XJ650 Turbo models (use 3 per bike), XJ750 Maxim and Midnight Maxim models (use 3 per bike), and XJ900RK Seca models (use 3 per bike). Each:
$ 4.00

HCP2322SET3 OEM inner fork tube air joint air valve and air hose O-RINGS. Set of 3:
$ 10.00



HCP8271 OEM inner fork tube air joint Air Valve and Hose O-Ring, fits the following models: XJ750 Seca (use 1 per tube) and XJ1100 models (use 3 per bike). Each:
$ 3.50

HCP8271SET3 OEM inner fork tube air joint Air Valve and Hose O-Rings. Set of 3:
$ 8.00



HCP9108 Aftermarket air-assisted forks LOW PRESSURE GAUGE, heavy-duty 0-20 psi pencil (stick) pressure gauge marked in 1/2-psi increments, perfect for checking fork air pressures on models so equipped. Very high quality and much more accurate than standard tire pressure gauges, which is very important on the fork pressures as an imbalance between the fork pressure can lead to steering and stability issues, while too much pressure can blow out the lower tube oil seals!
$ 4.95



Inner Fork Tube Retaining Hardware:


Your chrome fork tubes (properly called the "inner" fork tubes) are held to your bike via the upper and lower steering brackets. The upper bracket is called the "crown bracket" and your handlebars bolt to this bracket, while the lower bracket is called, quite logically, the under-bracket. The under-bracket has the large diameter rod that goes up through the steering neck tube (that is part of the frame), and within that tube are the steering neck Bearings. This rod is then bolted to the crown bracket after it has emerged from the top side of the frame steering neck tube.

The inner fork tubes are located in round bores on both sides of the upper crown bracket and the lower under-bracket. These bore are "split" and via proper tightening of the special Cinch Bolts, the proper tension is applied to firmly locate the fork tubes to the rest of the bike.

Replacement cinch bolts and their related hardware are available below:


Crown Bracket Inner Fork Tube Retaining Hardware:


HCP4529 OEM crown bracket fork tube CINCH BOLT,, use 1 per side. For the following models: XJ550 all models and 1980 XJ650 Maxim. Each:
$ 1.50

HCP4529SET2 OEM crown bracket fork tube CINCH BOLTS, use 1 per side. Pair:
$ 2.50



HCP4522 OEM crown bracket fork tube CINCH BOLT,, use 1 per side. For the following models: 1981-3 XJ650 all models except Turbo, and 1983 XJ750 Maxim and Midnight Maxim models. Each:
$ 1.25

HCP4522SET2 OEM crown bracket fork tube CINCH BOLTS, use 1 per side. Pair:
$ 2.00



HCP4531 OEM crown bracket fork tube CINCH BOLT,, use 1 per side. For the following models: XJ650 Turbo, and 1982 XJ750 Maxim, and all XJ750 Seca models. Each:
$ 1.75

HCP4531SET2 OEM crown bracket fork tube CINCH BOLTS, use 1 per side. Pair:
$ 3.00



HCP4946 OEM crown bracket fork tube CINCH BOLT,, use 1 per side. For the following models: all XJ700 models. Each:
$ 2.00

HCP4946SET2 OEM crown bracket fork tube CINCH BOLTS, use 1 per side. Pair:
$ 3.50



HCP4530 OEM crown bracket fork tube CINCH BOLT,, use 1 per side. For the following models: all XJ900RK Seca models. Each:
$ 1.25

HCP4530SET2 OEM crown bracket fork tube CINCH BOLTS, use 1 per side. Pair:
$ 2.00



HCP3945 OEM crown bracket fork tube FLAT WASHER,, use 2 per side. For the following models: all XJ550 models, 1981-3 XJ650 all models except Turbo, and 1983 XJ750 Maxim and Midnight Maxim models. Each:
$ 1.00

HCP3945SET2 OEM crown bracket fork tube FLAT WASHERS, use 2 per side. Pair:
$ 1.50

HCP3945SET4 OEM crown bracket fork tube FLAT WASHERS, use 2 per side. Set of 4:
$ 2.50



HCP2185 OEM crown bracket fork tube LOCK WASHER,, use 1 per side. For the following models: all XJ700 models. Each:
$ 1.00

HCP2185SET2 OEM crown bracket fork tube LOCK WASHERS, use 1 per side. Pair:
$ 1.50




HCP4528 OEM crown bracket fork tube CROWN NUT,, use 1 per side. For the following models: all XJ550 models and 1980 XJ650 Maxim models. Each:
$ 2.50

HCP4528SET2 OEM crown bracket fork tube CROWN NUT, use 2 per side. Pair:
$ 4.50



HCP4240 OEM crown bracket fork tube CROWN NUT,, use 1 per side. For the following models: all 1981-83 XJ650 models except Turbo, and 1983 XJ750 Maxim and Midnight Maxim models. Each:
$ 1.50

HCP4240SET2 OEM crown bracket fork tube CROWN NUTS, use 2 per side. Pair:
$ 2.50




Under-bracket Inner Fork Tube Retaining Hardware:


HCP3652 OEM under-bracket fork tube CINCH BOLT,, use 2 per side. For the following models: all XJ550 models, all XJ650 models, and all XJ750 Maxim models. Each:
$ 8.50

HCP3652SET4 OEM crown bracket fork tube CINCH BOLTS, use 2 per side. Set of 4:
$ 29.00



HCP3656 OEM under-bracket fork tube CINCH BOLT,, use 2 per side. For the following models: all XJ750 Seca and XJ900RK Seca models. Each:
$ 1.00

HCP3656SET4 OEM crown bracket fork tube CINCH BOLTS, use 2 per side. Set of 4:
$ 3.50



HCP4956 OEM under-bracket fork tube CINCH BOLT,, use 2 per side. For the following models: all XJ700 models. Each:
$ 1.95

HCP4956SET4 OEM crown bracket fork tube CINCH BOLTS, use 2 per side. Set of 4:
$ 6.50




HCP4955 OEM under-bracket fork tube CINCH BOLT,, use 2 per side. For the following models: all XJ1100 models. Each:
$ 8.50

HCP4955SET4 OEM crown bracket fork tube CINCH BOLTS, use 2 per side. Set of 4:
$ 29.95



HCP2185 OEM under-bracket fork tube LOCK WASHER,, use 2 per side. For the following models: all XJ750 Seca and XJ900RK Seca models. Each:
$ 1.00

HCP2185SET2 OEM crown bracket fork tube LOCK WASHERS, use 2 per side. Pair:
$ 1.50




LOWER (OUTER) FORK TUBE PARTS:



Dust Wiper Seals:

ft1) OEM and aftermarket lower fork tube Dust Wiper Seals will stop grit and moisture from entering the lower tube cavity and chewing up the oil seals. These dust wiper seals are the things you see at the very top of the lower fork tube.


HCP1820 OEM lower fork tube DUST WIPER SEAL, fits either left or right tube on the following models: all XJ550 Maxim and XJ650RJ Seca models. One seal does one tube. Each:
$ 11.50

HCP1820SET2 OEM lower fork tube DUST WIPER SEALS, one pair does both forks.
$ 21.00

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HCP1821 OEM lower fork tube DUST WIPER SEAL, fits either left or right tube on the following models: all XJ550 Seca models. One seal does one tube. Each:
$ 11.50

HCP1821SET2 OEM lower fork tube DUST WIPER SEALS, one pair does both forks.
$ 21.00

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HCP1823 OEM lower fork tube DUST WIPER SEAL, fits either left or right tube on the following models: all XJ650 Maxim and Midnight Maxim, 1982 XJ650 Turbo, and all XJ750 Maxim and Midnight Maxim. . One seal does one tube. Each:
$ 13.50

HCP1823SET2 OEM lower fork tube DUST WIPER SEALS, one pair does both forks.
$ 24.00

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HCP1824 OEM lower fork tube DUST WIPER SEAL, fits either left or right tube on the following models: all 1983 XJ650 Turbo models. One seal does one tube. Each:
$ 11.50

HCP1824SET2 OEM lower fork tube DUST WIPER SEALS, one pair does both forks.
$ 21.00

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HCP1825 OEM lower fork tube DUST WIPER SEAL, fits either left or right tube on the following models: all XJ700 models, chrome-capped as original. One seal does one tube. Each:
$ 16.95

HCP1825SET2 OEM lower fork tube DUST WIPER SEALS, one pair does both forks.
$ 29.95

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HCP1839 OEM lower fork tube DUST WIPER SEAL, fits either left or right tube on the following models: all XJ750 Seca models. One seal does one tube. Each:
$ 16.00

HCP1839SET2 OEM lower fork tube DUST WIPER SEALS, one pair does both forks.
$ 29.00

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HCP1822 OEM lower fork tube DUST WIPER SEAL, fits either left or right tube on the following models: all XJ900RK Seca models. One seal does one tube. Each:
$ 11.50

HCP1822SET2 OEM lower fork tube DUST WIPER SEALS, one pair does both forks.
$ 21.00

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HCP1826 OEM lower fork tube DUST WIPER SEAL, fits either left or right tube on the following models: all XJ1100 models. One seal does one tube. Each:
$ 16.00

HCP1826SET2 OEM lower fork tube DUST WIPER SEALS, one pair does both forks.
$ 29.00




Oil Seals:

ft1) OEM and aftermarket lower fork tube Oil Seals will stop those leaks and restore the performance to your front suspension and braking system. We offer three different grades of seals to satisfy everyone's needs:

a) OEM original equipment double-lip rubber seals provide the same quality and life expectancy as the originals. Although these are not the least expensive seals, no one ever went wrong with using original manufacturer products. Oil seals come with the internal tension spring when they were originally equipped as such.

b) Standard grade aftermarket double-lip BLACK OIL SEALS are the same or better quality than the OEM seals, but normally at a better price.

c) Premium grade aftermarket triple-lipped RED OIL SEALS are a significant new development in fork seal technology. Featuring a three independent sealing lips and dual tension springs, these seals use a patented elastomer rubber compound that not only allows for better oil seal characteristics, but are also designed to allow lower operating temperatures, which results in much longer seal life expectancy, as well as dramatically lowered seal "stiction" or "sliding friction coefficient"----a key feature of motorcycle fork seals. Lower friction prevents un-wanted fork movement resistance from occurring, for instance, when initially entering a corner, or braking. Ideally, you want the inner forks to move smoothly and without any "choppiness" past the lower tube seal, rather than a "starting and stopping" motion due to tube-to-seal "stiction". These seals deliver the lowest possible friction coefficient of any of our seals, and are well worth the extra cost!


ALSO---it's never a bad idea to use some of the 100% Silicone Grease as an "assembly lube" when installing any of these oil seals:

HCP1714 o-ring installation pure Silicone Grease:
$ 6.95




HCP1814 OEM lower fork tube OEM OIL SEAL, fits either left or right tube on the following models: XJ550 Maxim, XJ650 Maxim and Midnight Maxim, XJ650RJ Seca, 1982 XJ650 Turbo, and all XJ750 Maxim and Midnight Maxim models. One seal does one tube. Each:
$ 13.00

HCP1814SET2 OEM lower fork tube OIL SEALS, one pair does both forks.
$ 24.00


HCP1716 Aftermarket standard quality lower fork tube BLACK OIL SEALS, fits all of the following models: XJ550 Maxim, XJ650 Maxim and Midnight Maxim, XJ650RJ Seca, 1982 XJ650 Turbo, and all XJ750 Maxim and Midnight Maxim. Comes packaged as a pair of seals, enough to do both forks.
$ 17.00



HCP1908 Aftermarket premium quality lower fork tube RED OIL SEALS, fits all of the following models: XJ550 Maxim, XJ650 Maxim and Midnight Maxim, XJ650RJ Seca, 1982 XJ650 Turbo, and all XJ750 Maxim and Midnight Maxim. Comes packaged as a pair of seals, enough to do both forks.
$ 21.00

************

HCP1815 OEM lower fork tube OEM OIL SEAL, fits either left or right tube on the following models: XJ550 Seca models. One seal does one tube. Each:
$ 20.00

HCP1815SET2 OEM lower fork tube OIL SEALS, one pair does both forks.
$ 36.00


HCP1717 Aftermarket standard quality lower fork tube BLACK OIL SEALS, fits all of the following models: XJ550 Seca models. Comes packaged as a pair of seals, enough to do both forks.
$ 17.00

************

HCP1816 OEM lower fork tube OEM OIL SEAL, fits either left or right tube on the following models: 1983 XJ650 Turbo and XJ900RK models. One seal does one tube. Each:
$ 17.00

HCP1816SET2 OEM lower fork tube OIL SEALS, one pair does both forks.
$ 32.00


HCP1718 Aftermarket standard quality lower fork tube BLACK OIL SEALS, fits all of the following models: 1983 XJ650 Turbo and XJ900RK models. Comes packaged as a pair of seals, enough to do both forks.
$ 18.00

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HCP1817 OEM lower fork tube OEM OIL SEAL, fits either left or right tube on the following models: all XJ700 models. One seal does one tube. Each:
$ 15.00

HCP1817SET2 OEM lower fork tube OIL SEALS, one pair does both forks.
$ 29.00


HCP1719 Aftermarket standard quality lower fork tube BLACK OIL SEALS, fits all of the following models: all XJ700 models. Comes packaged as a pair of seals, enough to do both forks.
$ 18.00



HCP1909 Aftermarket premium quality lower fork tube RED OIL SEALS, fits all of the following models: all XJ700 models. Comes packaged as a pair of seals, enough to do both forks.
$ 21.00

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HCP1818 OEM lower fork tube OEM OIL SEALS, fits either left or right tube on the following models: all XJ750 Seca models. One seal does one tube. Each:
$ 13.00

HCP1818SET2 OEM lower fork tube OIL SEALS, one pair does both forks.
$ 24.00


HCP1720 Aftermarket standard quality lower fork tube BLACK OIL SEALS, fits all of the following models: all XJ750 Seca models. Comes packaged as a pair of seals, enough to do both forks.
$ 17.00

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HCP1910 Aftermarket premium quality lower fork tube RED OIL SEALS, fits all of the following models: all XJ1100 models. Comes packaged as a pair of seals, enough to do both forks.
$ 21.00




Oil Seal Retaining Clips:


HCP1827 OEM lower fork tube OIL SEAL RETAINING CLIP, fits either left or right tube on the following models: XJ550 Maxim, XJ650 Maxim and Midnight Maxim, XJ650RJ Seca, 1982 XJ650 Turbo, and all XJ750 Maxim and Midnight Maxim models. One clip does one tube. Highly recommended that these be replaced when replacing your oil seals! Each:
$ 7.00

HCP1827SET2 OEM lower fork tube OIL SEAL RETAINING CLIPS, one pair does both forks.
$ 12.50



HCP1828 OEM lower fork tube OIL SEAL RETAINING CLIPS, fits either left or right tube on the following models: 1983 XJ650 Turbo, all XJ700, and XJ900RK Seca models. One clip does one tube. Highly recommended that these be replaced when replacing your oil seals! Each:
$ 4.95

HCP1828SET2 OEM lower fork tube OIL SEAL RETAINING CLIPS, one pair does both forks.
$ 8.95




HCP1829 OEM lower fork tube OIL SEAL RETAINING CLIP, fits either left or right tube on the following models: XJ750 Seca models. One clip does one tube. Highly recommended that these be replaced when replacing your oil seals! Each:
$ 6.25

HCP1829SET2 OEM lower fork tube OIL SEAL RETAINING CLIPS, one pair does both forks.
$ 11.00




Oil Seal & Dust Seal Kits:


HCP6435 Aftermarket premium quality lower fork tube RED OIL & DUST SEALS KIT, fits all of the following models: XJ550 Maxim, XJ650 Maxim and Midnight Maxim, XJ650RJ Seca, 1982 XJ650 Turbo, and all XJ750 Maxim and Midnight Maxim. Comes with a pair of both the oil seals and the dust seals, enough to do both forks.
$ 36.00

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HCP1721 Aftermarket standard quality lower fork tube BLACK OIL SEALS & DUST WIPER SEALS KIT, fits all of the following models: all XJ700 models. Comes with one pair of both the oil and dust seals, enough to do both forks.
$ 39.95



HCP1715 Aftermarket standard quality lower fork tube FORK TUBE REBUILD KIT, fits all of the following models: all XJ700 models. Comes with one black oil seal and one chrome-capped dust wiper seal, the snap ring circlip and both metal slide rings, enough to do one fork tube.
$ 44.95

HCP1715SET2 Aftermarket standard quality lower fork tube FORK TUBE REBUILD KIT, fits all of the following models: all XJ700 models. Comes with a pair of both the oil and dust seals, the snap ring circlips and two sets of the metal slide rings, enough to do both fork tubes.
$ 84.95

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HCP1722 Aftermarket standard quality lower fork tube BLACK OIL SEALS & DUST WIPER SEALS KIT, fits all of the following models: all XJ750 Seca models. Comes with one pair of both the black oil seals and dust wiper seals, enough to do both forks.
$ 34.95

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HCP1723 Aftermarket standard quality lower fork tube BLACK OIL SEALS & DUST WIPER SEALS KIT, fits the following model: all XJ900RK Seca models. Comes with one pair of both the oil and dust seals, enough to do both forks.
$ 34.95



Lower Tube Metal Slider Bushings:

These split-ring bushings press into the lower tube, below the oil seal, and serves as a both a tube guide and absorbs the majority of the side loading of the inner tube as it passes through the lower tube. If the fork oil hasn't been changed regularly, grit and moisture in the oil eventually wear down these slides, which have a teflon-like coating on their inner bearing surface to eliminate resistance.

HCP3087 OEM lower fork tube METAL SLIDE BUSHING, fits either left or right lower tube on the following models: all XJ700 models. One slider does one tube. Each:
$ 14.00

HCP3087SET2 OEM lower fork tube METAL SLIDE BUSHINGS, set of 2:
$ 26.00



HCP3089 OEM lower fork tube METAL SLIDE BUSHING, fits either left or right lower tube on the following models: all XJ750 Seca models. One slider does one tube. Each:
$ 18.00

HCP3089SET2 OEM lower fork tube METAL SLIDE BUSHINGS, set of 2:
$ 33.00



HCP4259 OEM lower fork tube METAL SLIDE BUSHING, fits either left or right lower tube on the following models: all XJ900RK models. One slider does one tube. Each:
$ 12.00

HCP4259SET2 OEM lower fork tube METAL SLIDE BUSHINGS, set of 2:
$ 22.00



Lower Fork Tube Oil Drain Screw and Gasket:

These small phillips-head screws, near the bottom of the lower tubes, allows you to drain the tubes prior to doing an oil change, or before tube removal and dis-assembly for seal replacement or other service work. The gasket that goes behind this screw should always be replaced in order to prevent oil leaks.

HCP5187 OEM lower fork tube oil DRAIN SCREW, use one per tube. Natural finish, was originally black on models with black tubes. Fits all XJ-series bikes except XJ1100 models. Each:
$ 1.00

HCP7111 OEM lower fork tube oil drain screw GASKET, use one per tube. Fits all XJ-series bikes except XJ1100 models. Each:
$ 1.00



Lower Fork Tube Damper Rod Retaining Bolt and Gasket:

These large socket-head cap screws, on the very bottom of the lower tubes, retains the inner tube damper rods to the lower tubes, and must be removed before the chrome inner tube can be separated from the lower tube for dis-assembly for seal replacement or other service work. This screw is held in tight!----but it must be removed in order to take the fork upper and lower tubes apart in order to replace the lower tube seals, or any other internal parts. The HCP4402 Damper Rod Retaining Tool listed further below is needed to hold the damper rod itself (to prevent it from spinning freely) while this damper rod retaining screw is loosened and removed. The gasket that goes under this bolt should always be replaced in order to prevent oil leaks. These bolts, when installed, should be treated with a low-strength thread-locking compound.


HCP8233 OEM fork tube damper rod RETAINING SCREW. For all XJ550, XJ650, XJ700, XJ750 (except XJ750 Seca), and XJ900RK models. Use 1 per tube. Each:
$ 5.00

HCP8281 OEM fork tube damper rod RETAINING SCREW. For all XJ750 Seca and XJ1100 models. Use 1 per tube. Each:
$ 2.95


HCP8234 OEM fork tube damper rod retaining screw GASKET. For all XJ550, XJ650, XJ700, XJ750 (except XJ750 Seca), and XJ900RK models. Use 1 per tube. Each:
$ 5.50



Lower Fork Tube Axle Retaining Hardware:

A variety of fasteners were used to cinch the front axle shaft to the lower fork tubes. Note that models with the front axle in a leading position to the fork tubes only used one retaining bolt (on the right side lower fork tube), while models with the front axle along the lower fork tube centerline (BELOW the fork tubes) used two retaining bolts (one on each lower fork tube).


HCP4827 OEM front axle shaft-to-lower tube RETAINING BOLT, use 1 per bike on the right side lower fork tube. For all XJ550 Maxim, XJ650 Maxim, and 1983 XJ750 Maxim models.
$ 2.50

HCP4822 OEM front axle shaft-to-lower tube RETAINING BOLT, use 1 per bike on the right side lower fork tube. For all XJ650 Midnight Maxim, 1983 XJ750 Midnight Maxim, and XJ1100 models.
$ 1.50

HCP4828 OEM front axle shaft-to-lower tube RETAINING BOLT, use 1 per tube (2 per bike) on both the left and right side lower fork tube. For all XJ550 Seca, XJ650RJ Seca and XJ650 Turbo models, and XJ900RK models. Each:
$ 2.50

HCP2325 OEM front axle shaft-to-lower tube RETAINING BOLT, use 1 per tube (2 per bike) on both the left and right side lower fork tube. For all 1981-82 XJ550 Seca models, 1982 XJ750 Maxim and all XJ700 models. Each:
$ 4.50




HCP3945 OEM front axle shaft-to-lower tube retaining bolt FLAT WASHER, for all 1981 XJ550 Seca models. Use 1 per tube (2 per bike) on both the left and right side lower fork tube.
$ 1.00

HCP2537 OEM front axle shaft-to-lower tube retaining bolt FLAT WASHER, for all 1982-83 XJ550 Seca models, XJ650RJ Seca and XJ650 Turbo models, all XJ700-X models, XJ900RK models. Use 2 per retaining bolt (4 per bike) on both the left and right side lower fork tubes. (NOTE: XJ700-X models only use 1 of the washers be bike).
$ 1.00



HCP2185 OEM front axle shaft-to-lower tube retaining bolt LOCK WASHER, use 1 per bike on the following models: all XJ550 Maxim models, all XJ650 Maxim models, all XJ700 models, 1982 XJ750 Maxim models, and XJ1100 models. Use 2 per bike on the following models: all 1981 XJ550 Seca, XJ650RJ Seca and XJ650 Turbo models, and XJ900RK models.
$ 1.00

HCP2391 OEM front axle shaft-to-lower tube retaining bolt LOCK WASHER, use 1 per bike on the following models: all XJ650 Midnight Maxim models and XJ750 Midnight Maxim models. Use 2 per bike on the following models: all 1982-83 XJ550 Seca models.
$ 1.25

HCP4824 OEM front axle shaft-to-lower tube retaining bolt LOCK WASHER, use 1 per bike on the following models: all XJ750 Seca models.
$ 1.75



HCP3494 OEM front axle shaft-to-lower tube retaining bolt NUT, use 1 per bike on the following models: all XJ550 Maxim models, all XJ650 (except Midnight Maxim) models, all XJ700 non-X models, and all XJ750 (except Midnight Maxim) models. Use 2 per bike on the following models: all XJ550 Seca and XJ900RK models. Each:
$ 1.50

HCP3495 OEM front axle shaft-to-lower tube retaining bolt NUT, use 1 per bike on the following models: all XJ650 Midnight Maxim and all XJ750 Midnight Maxim models. Each:
$ 1.25

HCP4821 OEM front axle shaft-to-lower tube retaining bolt NUT, use 1 per bike on the following models: all XJ700-X models. Each:
$ 2.50




FORK OIL:


Unlike motor oil or gear oil, fork oil's major purpose is not lubrication.....rather, it acts as part of the suspension system, providing both damping and rebound control functions. The different "weight" or viscosity of fork oils allows you to modify the ride and handling characteristics of your bike in a fairly simple way.

And yes, it IS a lubricant also!

Although many people----including, uneblievably, Yamaha itself----recommends the use of engine motor oil as a substitute for fork oil, this is not a very good idea. Engine oils (or any multi-viscosity oil) uses additives and detergents that, while wonderful in for their intended purposes inside an engine block, tranny case, or rear drive unit, are not such a good idea inside forks. Forks operate at a much lower temperature and temperature RANGE than engine and drivetrains do, and thus do not need all those additives. And fork oil also tends to contain higher percentages of molybdenum disulfide and anti-foaming agents than engine or gear oil, both of which are very important to proper fork operation.

As a small example.......most motor oils are of a multi-viscosity nature (such as 10W30) which change their viscosity in relation to their temperature (thin when cool, thicker as they warm). A very necessary and useful feature for an engine, where you do not want your oil thinning out as the engine warms up. Not such a good idea for your suspension----unless for some reason you WANT your handling characteristics to change (get stiffer) as the forks heat up!

Proper fork oil levels and scheduled change intervals are important for fork performance and fork part longevity.....water contamination, as well as particulate wear will accumulate in fork oil, and since there is no oil filtering mechanism within your forks, the only way to get the grit and gunk out (before it chews up your oil seals and slider bearings!) is to change your fork fluid regularly. Yamaha recommends a fork fluid change every 10-15,000 miles or every 2 years. If you just bought a used bike, we recommend you do a fluid change as soon as possible, because just like other routine maintenance tasks (besides engine oil changes), this is one that has very likely been ignored for the last 10-12 years!

Fork oil capacities and recommended weights are as follows. The amounts listed are per fork tube:

XJ550 Maxim: 272cc or 9.20 fluid ounces. 10W fork oil.

XJ550 Seca: 230cc or 7.78 fluid ounces. 10W fork oil.

1980-81 XJ650 Maxim and Midnight Maxim: 262cc or 8.86 fluid ounces. 10W fork oil.

1982-84 XJ650 Maxim: 278cc or 9.40 fluid ounces. 10W fork oil.

1982 XJ650RJ Seca: 236cc or 7.98 fluid ounces. 10W fork oil. Fork oil level is specified as 400mm (15.75") below the top of the tube without the spring installed, forks fully collapsed.

1982 XJ650LJ Turbo: 238cc or 8.04 fluid ounces. 10W fork oil. Fork oil level is specified as 180mm (7.09") below the top of the tube without the spring installed, forks fully collapsed.

1983 XJ650LK Turbo: unknown.

1985-86 XJ700 non-X: 383cc or 12.96 fluid ounces. 10W fork oil.

1985-86 XJ700-X: 389cc or 13.16 fluid ounces. 10W fork oil.

1982 XJ750 Maxim: 257cc or 8.69 fluid ounces. 10W fork oil.

1983 XJ750 Maxim and Midnight Maxim: 257cc or 8.69 fluid ounces. 10W fork oil. NOTE: owner's manual states that the fork oil capacity is 278cc (9.40 fluid ounces). It is unknown which measurement is correct.

1981-83 XJ750 Seca: 309cc or 10.45 fluid ounces. 20W fork oil.

1983 XJ750 E-II Seca or 1984 XJ750RL Seca: 286cc or 9.67 fluid ounces. 5W fork oil. Fork oil level is specified as 168mm (6.61") below the top of the tube without the spring installed, forks fully collapsed.

1983 XJ900RK Seca: 286cc or 9.67 fluid ounces. 5W fork oil. Fork oil level is specified as 164mm (6.46") below the top of the tube without the spring installed, forks fully collapsed.

1982-84 XJ1100 Maxim and Midnight Maxim: 210cc or 7.10 fluid ounces. 10W fork oil. Fork oil level is specified as 210mm (8.27") below the top of the tube without the spring installed, forks fully collapsed.

IMPORTANT NOTE: the above fork oil VOLUMES are for use only when using the stock fork springs. The use of aftermarket performance front fork coil springs [will change those volumes, since aftermarket springs are thicker than stock----and thus displace more oil. Using the stock oil fluid VOLUME with aftermarket fork springs is a sure way to OVERFILL your forks, with the very real possibility of blowing out fork seals.

Unlike with your engine oil, where a bit too much or too little oil volume in the crankcase is not really a significant concern, with fork oil, too much or too little can cause real problems (too much oil can result in blown oil seals and a stiff, harsh ride, while too little oil volume results in excessive foaming, a soft mushy ride with possible bottoming, and erratic fork performance and lots of front end "dive" upon braking).

A better way to determine the amount of fork oil that is needed and necessary is via the measurement of the fork oil LEVEL within the tubes.....sort of like measuring the oil level with a dipstick. Yamaha does not specify this level for all models; and in any case, if using aftemarket springs, the factory oil level recommendation is not always useful. The maximum oil level should be 5-1/2" (140mm) below the top of the inner fork tube, measured with all internal fork tube components installed EXCEPT FOR THE SPRINGS, and with the inner fork tube fully collapsed into the lower (outer) tube.

In order to be as accurate as possible, we recommend the use of a suitable measuring device, such as the HCP1728 oil level syringe listed further below.

And finally, the fork oil viscosity can be changed from the factory recommendations to give a softer or firmer ride.......the lower the viscosity, the thinner the oil, and the softer the ride (i.e. 5W oil is thinner than 10W which is thinner than 20W, etc.) In this regard, you would certainly be correct in thinking of fork oil as a suspension "tuning tool"! Note that a thicker oil viscosity will have much more effect on the fork "rebound" characteristics than it will on the fork compression dampening function.



Fork Tools:


w) Lower Fork Tube DAMPER ROD RETAINING TOOL.....long aluminum tool with proper sized nuts on each to retain the top of the fork damper down in the bottom of the tube when removing or installing the dampers. One end has a 19mm hex and the other end has a 22mm hex, so it will fit all styles of XJ forks that require the use of this damper retaining tool.

HCP4402 Fork Rod Damper Retaining Tool:
$ 18.95



HCP9238 Aftermarket fork upper cap bolt REVERSE HEX SOCKET TOOL. This tool allows the easy removal and installation of the "inverted/reversed" hex-drive cap bolt used on the top of the inner fork tubes on all XJ650 Turbo, XJ700 non-X, and XJ900RK models.
$ 12.95



HCP9208 Fork Tube DEEP REACH CLEANING BRUSH. This 30" long handled brush features vinyl-covered wires that can reach deep inside the forks tubes to clean away grit and residue that cannot otherwise be reached or disturbed. Use with your favorite cleaning solvents to get the insides of the fork tubes free of contaminants.
$ 9.95



HCP1728 Fork tube oil fluid level measurement GAUGE AND SYRINGE. This handy tool makes the measurement of the fork oil level easy and accurate. NOTE: the proper amount of fork oil is determined via the measurement of the fork oil LEVEL (distance below the very top of the inner tube) rather than a volume AMOUNT of oil specification. Too little oil will make the ride mushy, while too much oil makes the ride harsh (and can blow out the oil seals!)
$ 34.95

 

Thanks guys. That'll do it!

Dean