how do i Remove fork seals

[eltoroloco]

I have a manual and i'm following the directions to the letter and the allen bolt at the bottom of the fork just wont come out. Its a 1980 xs1100G. When it turns it turns with somthing inside the fork, i cant see what it is too well because its down there pretty far. If anyone has insight into this problem i'd love to know how its done. (I assume that the fork has to come all the way apart to replace the seal, not really sure though) Please help, my bike is getting so close to finished but these darn forks leak oil like crazy.

[ratbyk]

Lower Fork Sliders

That bolt can be a major problem. When I encounter a difficult one I:
1. Take a torch, (propane will do but oxy/acetylene is faster) and heat up the troublesome bolt. Not to red hot or anything but hot enough to soften the loctite that was used during assembly.
2. Use an impact gun to shock the bolt loose and off. You will need an allen socket for this.
3. If it still won't come loose, take a piece of 5/8 wooden dowel and taper the end slightly. Run it down in, so that the taper portion slides into the internal piece that the lower bolt threads into. Tap it in securely with a hammer to jam the piece to prevent it turning and again hit the bolt with the impact gun.
Be persistent and a bit force-full, it will come loose and out.
Ken?Sooke
78E Ratbyk
82 FT500 "lilRat"

[eltoroloco]

Great, sounds like youve got a lot of experience with that bolt. thank you very much for the advice.

[strom]

I used thin pipe, bashed a bit at the end to make an irregural shape, welded onto a steel rod. Hammered it in, took out the stuff.

LP

[eltoroloco]

I got it. I took a discarded broom handle, used an utility knife to make a spike. After securing the insides the bolt just needed some heat (about 30 seconds with a torch) the bolt came loose by hand. thanks a bunch.

[TopCatGr58]

Just wanted to mention NOT to forget the Locktite when you put it back together, it states that in the manual, but wanted to make sure you didn't overlook it, would not be fun to accellerate one day and have the front wheels and lower forks fly off the bottom!!
T.C.

[eltoroloco]

Thanks for the concern, i did remember the thread lock.

I was shocked at how much oil leaked out. there was supposed to be 250 ml in each fork but there was only about 40-50 left. The seals that i bought from partsnmore.com fit very well, as far as i can tell they are functioning well, time will be the test of that one however.

[skids]

What brand did they sell you?

Originally posted by eltoroloco
The seals that i bought from partsnmore.com fit very well, as far as i can tell they are functioning well, time will be the test of that one however.

[tctenng]

After fighting mine with allen wrenches and extensions, I got smart and whipped out my impact gun and broom, broom they were out. I didn't have to fight hold the slider at all. I just held the fork in my hand, pulled the trigger and out they where.
If you don't have an impact gun, I bet if you took your forks and the right alen socket and a 3/4-1/2 adapter up to a tire shop or garage, they would do it for you.

gregg

[John]

Hey Gregg

Have you done the brake installation yet? If so, how did it work?

[eltoroloco]

The lable reads on the fork seals

PARTS+PLUS
performance equiptment
27-1012

As for the brakes i've taken them completely apart about a month ago to rebuild. New rubber parts were a must the bike had been sitting for years. AFter that i repainted them gloss black with a brake caliper paint called plasticoat. it seems to have good chemical resistance. i not ready to reinstall the brakes because i have another fork to do. I live in Illinois, and we just got a hell-of-a-lota snow. Plowing is no fun but time and a half pay is.