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xs650 > > Motorcycle Systems > > Frames > > Need Advice removing lower fork legs |
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Need Advice removing lower fork legs
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madskills 650Rider Supporter
Joined: Mar 28, 2006 Posts: 59
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Posted: August 23, 2006, 9:49 pm Post subject: Need Advice removing lower fork legs |
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I am disassembling my forks as I want to powdercoat them as well as rebuild the forks and am having troubles, I cannot get the damper rod bolt loose, my manual says to take a 1/2" and flatten to 10MM and slide in which should grasp the milled flats of the rod, ahh they make it sound so easy, any help is greatly appreciated.
John
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Cafe_Shop 650Rider Supporter
Joined: Jun 02, 2006 Posts: 228 Location: Grand Rapids, MI
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Posted: August 23, 2006, 11:31 pm Post subject: Re: Need Advice removing lower fork legs |
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Here's what you need if you have a 77 or newer xs:
a 2 foot long 7/16 threaded rod and a half dozen 7/16 nuts (they are .675" across the flats)
Lock the nuts together on the threaded rod like in the picture.
Slide the rod into the fork tube. It will fit in the socket at the bottom of the tube and allow you to remove the screw in the end of the tube.
I figured this out after breaking a wooden dowel off in my first attempt.
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jayel 650Rider Supporter
Joined: Apr 16, 2006 Posts: 3417 Location: SE Iowa 1974 TX650A
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Posted: August 23, 2006, 11:38 pm Post subject: Re: Need Advice removing lower fork legs |
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Damper Bolt Driver - Deep type damper bolt driver used to air impact recessed damper bolts from lower fork legs.
if you have one of this from mikesXS you can normal spin the allen head bolts out of the bottom of the legs it's a long 8mm allen (hex) works better than trying to remove them by hand
_________________ all it takes is time and money -- Where are we going and why are we in this hand basket? |
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Cafe_Shop 650Rider Supporter
Joined: Jun 02, 2006 Posts: 228 Location: Grand Rapids, MI
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Posted: August 23, 2006, 11:42 pm Post subject: Re: Need Advice removing lower fork legs |
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jayel wrote: |
Damper Bolt Driver - Deep type damper bolt driver used to air impact recessed damper bolts from lower fork legs. |
It takes more than just the bolt driver. I bought one from Mike's and all it did was spin the bolt and damper rod. You have to have a tool to hold the damper rod as well.
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madskills 650Rider Supporter
Joined: Mar 28, 2006 Posts: 59
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Posted: August 27, 2006, 9:57 am Post subject: Re: Need Advice removing lower fork legs |
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Thanks cafe, seems like a cheap route to go I'll give it a try, appreciate the help
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royfisk Full Member
Joined: May 24, 2006 Posts: 1597 Location: winchester, new hampshire usa
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Posted: August 27, 2006, 10:45 am Post subject: Re: Need Advice removing lower fork legs |
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Both Jayel and cafe shop are correct. 90% of the time jayels method works great. But then there is that10% that just will not come loose. I have one right now that is off of a 81, that not only wouldnt impact out but also would not come apart with the damper rod locked, broke off the end of the rod in the lower leg. Now there is a problem. I put everything away and built another set of forks, but still need to save these somehow>
_________________ build them , ride them, tear them down, rebuild them, ride them, etc. etc. etc.. They only get better and better |
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jayel 650Rider Supporter
Joined: Apr 16, 2006 Posts: 3417 Location: SE Iowa 1974 TX650A
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Posted: August 27, 2006, 1:57 pm Post subject: Re: Need Advice removing lower fork legs |
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about all you can do with that one roy is stop it from rotating (drive a wooden dowel into the broken end) and drill the head off the bolt
_________________ all it takes is time and money -- Where are we going and why are we in this hand basket? |
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madskills 650Rider Supporter
Joined: Mar 28, 2006 Posts: 59
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Posted: September 3, 2006, 2:37 pm Post subject: Re: Need Advice removing lower fork legs |
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Thanks for all the advice guys, a smashed thumb later(ouch) I was able to finally break the damn things free, Cafe, thanks I took your advice and now have a Fork leg tool that worked, now a little bead blast and ready to powdercoat.
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madskills 650Rider Supporter
Joined: Mar 28, 2006 Posts: 59
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Posted: September 4, 2006, 9:48 pm Post subject: Re: Need Advice removing lower fork legs |
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Well not quite ready yet, now requesting advice on getting the damn seals out? Are there any tricks? Seem to be very stubborn.
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Skogga New Member
Joined: Apr 20, 2006 Posts: 8
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Posted: October 21, 2006, 8:52 pm Post subject: Re: Need Advice removing lower fork legs |
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Earlier I had bought a set of hex sockets which included a 17mm, but the collar was too big to slide down the fork tube! Fortunately the hex itself was held in the drive collar by a small set screw, that loosened I took the hex out and taped it into a Stanley 17mm socket which fit down the tube. I had just enough extensions to make it to the damper with the boot all the way up. Using Mike's 8mm extended driver on the bottom the parts came off easily.
_________________ "Wage war on the Eye which cannot see, Destroy the Temple of Emptiness" |
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5twins Full Member
Joined: Aug 05, 2006 Posts: 1616
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Posted: October 22, 2006, 12:09 am Post subject: Re: Need Advice removing lower fork legs |
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deleted
Last edited by 5twins on September 13, 2009, 12:17 pm; edited 1 time in total |
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Cafe_Shop 650Rider Supporter
Joined: Jun 02, 2006 Posts: 228 Location: Grand Rapids, MI
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Posted: October 22, 2006, 11:55 am Post subject: Re: Need Advice removing lower fork legs |
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Well what do you do when you've removed the ring and the seal still won't budge?
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