1. Some members were not receiving emails sent from XJbikes.com. For example: "Forgot your password?" function to reset your password would not send email to some members. I believe this has been resolved now. Please use "Contact Us" form (see page footer link) if you still have email issues. SnoSheriff

    Hello Guest. You have limited privileges and you can't "SEARCH" the forums. Please "Log In" or "Sign Up" for additional functionality. Click HERE to proceed.

Issues removing damper rod and clutch nut

Discussion in 'XJ Technical Chat' started by scoobydew, Sep 12, 2020.

  1. scoobydew

    scoobydew Member

    Messages:
    145
    Likes Received:
    16
    Trophy Points:
    18
    Location:
    new york
    Hey guys. Sorry to keep bombarding ya'll with questions but I can only find bits and pieces of info I need on youtube and on this site. So I've run up into a wall. I'm trying to take apart my front forks. I was trying to remove the allen bolt at the bottom of the forks but they "free-floating". So the Hayne's manual says I need some long socket to hold onto the damper rod while I unscrew the allen bolt. I could search for this tool they provide or make my own. Issue is, they don't say what size the socket to fit on the damper rod should be...

    I have searched this site and found some guides like this one:
    https://www.xjbikes.com/forums/threads/doing-the-750-secas-forks-rebuild-now-a-how-to.18730/

    [​IMG]
    But he holds the fork with an extension and torques the allen. I kind of did the same but it doesn't seem to work. I'm guessing I need to find something to hold onto the damper rod inside. Anyone jerry-rig something to take care of this issue?

    Also! What size socket is needed to remove this nut? I have a 27mm and it's too small...
    [​IMG]
     
  2. Simmy

    Simmy Well-Known Member

    Messages:
    2,440
    Likes Received:
    1,221
    Trophy Points:
    113
    Location:
    Waterloo Ontario Canada
    I have a 3/8" drive extension, it is about 24" long.
    Stick a spark plug socket on backwards and you have your damper rod holding tool.
    The clutch nut needs a 30 mm socket.

    fork damper.JPG
     
  3. scoobydew

    scoobydew Member

    Messages:
    145
    Likes Received:
    16
    Trophy Points:
    18
    Location:
    new york
    Hey thanks a bunch! Where would we DIY mechanics be if it wasn't for internet and great community like you guys.

    Apologies I forgot to mention what bike model I have. I dunno if it changes from model to model. It's an XJ750 Seca. Just in case that size spark plug socket doesn't fit. So a 13/16 upside-down spark plug socket and 24' extension should do eh? I''ll put those on order!
     
  4. Franz

    Franz Well-Known Member

    Messages:
    4,120
    Likes Received:
    1,164
    Trophy Points:
    113
    Location:
    Scotland UK.
    15999913465251468513299464610739.jpg 15999915867416510401611452951601.jpg 15999917208831677558575288344531.jpg

    Left Haynes should put the size of the tools needed with their pictures.

    Centre picture is the 22mm top hacksawed off an old coil spring compressor which is half inch drive.

    Right DIY clutch basket holding tool made out of metal bar and an old light fitting. Never throw anything away. Having said that clutch holding tools are not expensive but mine was easy to make.

    Good idea Simmy with the spark plug socket.
     
    Last edited: Sep 13, 2020
    scoobydew likes this.
  5. Rooster53

    Rooster53 Well-Known Member Premium Member

    Messages:
    1,964
    Likes Received:
    780
    Trophy Points:
    113
    Location:
    North, FL
    scoobydew, k-moe and Franz like this.
  6. XJ550H

    XJ550H Well-Known Member Premium Member

    Messages:
    13,199
    Likes Received:
    3,861
    Trophy Points:
    113
    Location:
    Great North Woods
    I bolt the fork tube down to a bench or plywood using the fender mount holes. then heat up the allen bolt to soften the thread lock compound works well.
    the tool is not needed untill the allen is loosened it is just to hold spinning part in place

    you can use a broom handle as the tool for the forks

    I would recomend a set of digital calipers for your tool box very handy to have
    [​IMG]
     
    Last edited: Sep 19, 2020
  7. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

    Messages:
    19,647
    Likes Received:
    6,755
    Trophy Points:
    113
    Location:
    The City of Seven Hills
    It matters quite a lot, depending on what part of the machine you are working on.
    On your profile page you can add a signature with the model and year of XJ you have.
     
    scoobydew likes this.
  8. scoobydew

    scoobydew Member

    Messages:
    145
    Likes Received:
    16
    Trophy Points:
    18
    Location:
    new york
    I actually got one out without any holder. Just used a manual impact driver, hit it with a rubber mallet a few times and it came lose. However, big issues. One of them was pretty rounded out already and I just ended its hex socket life.... I already gotta take two pieces to the machine shop. Gonna try to remove this one by sacrificing a hex bit with some JB Weld in the allen socket and let the bit sit for a while. Hopefully it can take a smack from the impact driver again
    [​IMG]
     
  9. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

    Messages:
    19,647
    Likes Received:
    6,755
    Trophy Points:
    113
    Location:
    The City of Seven Hills
    Those problems are annoying. If she won't come free just drill the head off. You can remove the stub later.

    Next time you run into that use a slightly oversize Torx bit. Hammer it into the fastener and it'll bite enough.
     
  10. Dave in Ireland

    Dave in Ireland Well-Known Member

    Messages:
    621
    Likes Received:
    358
    Trophy Points:
    63
    Location:
    Ireland
    They're really handy for clamping a tea tray to the bench.
     
    chacal likes this.
  11. k-moe

    k-moe Pie, Bacon, Bourbon. Moderator Premium Member

    Messages:
    19,647
    Likes Received:
    6,755
    Trophy Points:
    113
    Location:
    The City of Seven Hills
    Philistine :p
     

Share This Page