XJ650 RJSECA PROG SPRINGS - PLUG SEIZED IN TOP OF FORK TUBE

:? Hi XJ
I am attempting to replace my old front fork springs with new progressive ones.
Managed to get one seized plug out of top of one fork, but the other won't budge. (tried soaking in freeing oil for two nights)
Pic to follow, but in the meantime, has anyone come across this before, and any ideas or tips to overcome this?
Regs.
Dale Grantham

 

You MUST get that out..... I'd recommend using a socket that is slightly smaller than the diameter of the tube-- hold it on top of the plug and give it a few sharp whacks with a good hammer to break the rust. Remember there is a circlip that you have to get to, so you have to get that plug to depress.

Next step would to heat the tube carefully then try the socket/hammer thing again.

If that doesn't work, you'll probably end up at a machine shop so the fork can be put in a vise or press to depress the plug....

 

Re: XJ650 RJSECA PROG SPRINGS - PLUG SEIZED IN TOP OF FORK T

Hi hog
Thanks for reply
The circlip is already out - hammered on the top of the plug with half diameter of fork nut and threaded rod (after soaking, that's how I got the other one out!) The plug is only about 1-2mm below the circlip groove, but stuck fast.
I've tried freeze spray also.
Will try putting in a vice, and your recommendations using socket. (I won't force the plug past a groove or anything will I, and make it worse!) :?
Regs.

 

If you don't mind making a mess, and have a scissor jack (or better yet a hydraulic bottle jack), you can probbly get the cap to pop out.

Lay the jack, and fork leg on your garage floor, or driveway in the following order: Wall > jack > fork leg > car tire (still on the car).

You now have a makeshift 2 ton press. Extend the jack to compress the fork. Since the circlip is out, the pressure from the jack should pop the cap out before the fork seals blow. There will be a mess, so prepare accordingly.

You also may consider running some 800 grit finishing paper around the inside radius of the upper fork tube to clean it of any corrosion that may be hampering the cap's release.

 

Get a 2by4 flip the shock upside down and go to town worked for me.



Have some rags near you.

 

Re: XJ650 RJSECA PROG SPRINGS - PLUG SEIZED IN TOP OF FORK T

My vice is broke. Seized up also, I think!
Would it be ok to put fork back in yoke, tighten up all available and then hammer down on a socket on top? I've tried all the methods mentioned, but I can't get the necessary percussion, cos the fork is compressing when I hammer.

 

Re: XJ650 RJSECA PROG SPRINGS - PLUG SEIZED IN TOP OF FORK T

Put back in fork stanchion and tightened up. Hammered with slightly smaller socket diameter many times........Nothing!
See pics. think I'm gonna need blowlamp?

 

I spent a week trying everything. Till I read a post here. Take the fork off the bike turn it upside down. Have a piece of wood on the floor. Take the top of the fork and set it on the wood. Take both hands lift the fork up and come down on the piece of wood. After a couple time you will see the cap starting to come off. If you don't do it harder. There will be a mess but your cap should come off. I did this to both of mine. It's the only way I could get the caps out off. There all back together riding everyday with no leaks.

Hope this helps.

 

Re: XJ650 RJSECA PROG SPRINGS - PLUG SEIZED IN TOP OF FORK T

side view

 

Re: XJ650 RJSECA PROG SPRINGS - PLUG SEIZED IN TOP OF FORK T

Tried that already, bounced it up and down about 20 times. I have no oil left in fork now though, cos drained it. Would that make it less likely to free the plug? (will try that again anyway)
Did you try the heating method also?

 

Yes tried the heat nothing. I then got some "kroil" (fitz recommended) let that sit for a while then I went on to hitting the on the wood and they popped right off.

 

If you dont have Kroil. Mix 50% automatic transmission fluid with 50% acetone. apply and let it soak.

 

If all else fails: use the kroil or atf mix as suggested then go to lowe's or home depot and buy a furniture clamp that is long enough to reach both ends of the fork. Put a small metal plate over top of the fork then use the clamp to compress the fork. You should hear the cap smack against the inside of the plate. Same concept as k-moe suggest.

Gary

 

Re: XJ650 RJSECA PROG SPRINGS - PLUG SEIZED IN TOP OF FORK T

Thank-You all!
Just in process of getting some Kroil (it's called PlusGas over here)
Soon as I've acquired it I will try out every method, till I've got the +*%&^ out!
Will keep you posted - fingers crossed! :wink:
Regs

 

if a guy was to drill and tap that plug while it's still tight he could rig up a slide hammer and pop it right out. then put a set screw in the hole to plug it

 

That's a great idea Polock. Just sent for a slide hammer (£10 UK). The 'kroil and bang' method might work eventually, but I've had @ 6 goes in the past two days, and the plug hasn't budged a mm!
A furniture clamp might also work, but that would have set me back £20, and not absolutely sure.....?
After investigating how they work, (the slide hammers) I'm pretty sure this will solve the issue.
And yes, just pop a flat topped grub screw into the hole that's left to seal it up again.

 

Re: XJ650 RJSECA PROG SPRINGS - PLUG SEIZED IN TOP OF FORK T

I'm back with results of the seized-in plug!
This may be valuable material for future members with same problem...cos not seen it mentioned in XJBikes before..(it may have been)?
Well - I eventually got that plug out, but not by any of the methods mentioned as such because:
I bought a slide hammer (£10) but it would have cost another £10 Uk for a 12mm metric 'fine' tap to match the end thread of the hammer (total £20!)
I had tried all the others methods, apart from the furniture clamp, (which would have cost me £20 again).....so: This is a cheap and easy method...
A friend of mine came across and suggested I drill a 9mm whole all the way through the centre of the plug, and then run a 10mm (regular) tap through that.
Next, got a 10mm thick flat steel bar (about 5" long - it only needs to be long enough to extend about an inch either side of the diameter of the tube top) and drilled a 10mm hole in the centre of that.
Put the bar across the top of the tube plug-hole.....offer up a 10mm, 4" long bolt through the bar hole, and into the tapped out hole in the plug.....and T-U-R-N, slowly......
Acts exactly like an extractor tool, and out popped the plug!
Next, shear the head off the bolt you used close as possible to the top surface of the plug with angle grinder, and smooth off using bench grinder.....the hole in the plug is sealed up again completely flush either end!
Installed the springs, oil, washers and spacers, cleaned the plugs and reinstalled them along with the circlips, and away I go!
I can tell the difference in handling straight away, especially turning bends at speed with uneven camber. Also smoother when going over bumps, potholes.
It may need a bit of extra pre-load perhaps, but that is no problem, - just either add a few more ml oil to each fork, and/ or increase the spacer length in 1/4" increments.
Thanks for all your help, everyone....
Regs.

 

Good deal. If you notice that the air pressure is dropping (I assume you have the air forks), dab a bit of 2-part epoxy over the bolt to seal it. Evne the best fasteners only have 20% of the thread surfaces in contact with one another, so there is a lot of room for air to pass by the fastener (albeit slowly).

 

Re: XJ650 RJSECA PROG SPRINGS - PLUG SEIZED IN TOP OF FORK T

Yes, good point that. I was going to plug the whole of the hole in the plug with epoxy until I thought of keeping the bolt in!
I'll keep my eye on it, and take your advice if I notice anything amiss. (will oil perhaps eventually seep in between the threads, up to the surface?)
Regs.