Hi all. I've got a thread over in the Suspension Forum that's not getting the amount of response that I had hoped for. Hoping you guys here in the XR forum might be able to help, too. Thanks!
http://www.thumperta...ad.php?t=830408
XR600R Fork Disassembly Frustration. Help!
Started by BackinAction, Oct 04 2009 09:34 AM
7 replies to this topic
Posted 04 October 2009 - 09:34 AM
Hi all. I've got a thread over in the Suspension Forum that's not getting the amount of response that I had hoped for. Hoping you guys here in the XR forum might be able to help, too. Thanks!
http://www.thumperta...ad.php?t=830408
Posted 04 October 2009 - 10:02 AM
where the dust seals meet the fork tubes take a screwdriver or chisel and tap the dust seals lip up and out w/ a hammer...as it starts comming out work ur way around the perimeter evenly...
once the dust seals r out u'll see the snap ring that has to be removed before u can take the oil seals out/remove tubes from sliders...
once that's done(snap ring removal) plus draining as much oil as possible...u then "hammer" the tubes and oil seals outta the sliders watching not to get oil all over the ceiling, etc...:smirk:
the dust seals removal is not very well explained as u r finding out but after u do it once it's easy :thumbsup:
:cheers:
P.S. w/o a special seal driver it will take alot of force to drive("hammer") the new seals into place :smirk:
once the dust seals r out u'll see the snap ring that has to be removed before u can take the oil seals out/remove tubes from sliders...
once that's done(snap ring removal) plus draining as much oil as possible...u then "hammer" the tubes and oil seals outta the sliders watching not to get oil all over the ceiling, etc...:smirk:
the dust seals removal is not very well explained as u r finding out but after u do it once it's easy :thumbsup:
:cheers:
P.S. w/o a special seal driver it will take alot of force to drive("hammer") the new seals into place :smirk:
Posted 04 October 2009 - 12:27 PM
once that's done(snap ring removal) plus draining as much oil as possible...u then "hammer" the tubes and oil seals outta the sliders watching not to get oil all over the ceiling, etc..
And by the word "Hammer" Kenzos used there he means put the bottom part of the leg in a vice using whatever holding method you can come up with. Theirs a couple of flat lugs on the bottom fork part that are suitable for the vice..then push down and pull up about a dozen times on the top leg using a fair amount of strength..The oil seals should pop eventually and it'll all come to bits in your hands..It takes a fair amount of "hammering" for them to separate so don't be afraid to apply Superhuman powers.
And by the word "Hammer" Kenzos used there he means put the bottom part of the leg in a vice using whatever holding method you can come up with. Theirs a couple of flat lugs on the bottom fork part that are suitable for the vice..then push down and pull up about a dozen times on the top leg using a fair amount of strength..The oil seals should pop eventually and it'll all come to bits in your hands..It takes a fair amount of "hammering" for them to separate so don't be afraid to apply Superhuman powers.
Posted 04 October 2009 - 02:13 PM
Horri said:
once that's done(snap ring removal) plus draining as much oil as possible...u then "hammer" the tubes and oil seals outta the sliders watching not to get oil all over the ceiling, etc..
And by the word "Hammer" Kenzos used there he means put the bottom part of the leg in a vice using whatever holding method you can come up with. Theirs a couple of flat lugs on the bottom fork part that are suitable for the vice..then push down and pull up about a dozen times on the top leg using a fair amount of strength..The oil seals should pop eventually and it'll all come to bits in your hands..It takes a fair amount of "hammering" for them to separate so don't be afraid to apply Superhuman powers.
And by the word "Hammer" Kenzos used there he means put the bottom part of the leg in a vice using whatever holding method you can come up with. Theirs a couple of flat lugs on the bottom fork part that are suitable for the vice..then push down and pull up about a dozen times on the top leg using a fair amount of strength..The oil seals should pop eventually and it'll all come to bits in your hands..It takes a fair amount of "hammering" for them to separate so don't be afraid to apply Superhuman powers.
...and if that doesn't work...relax...drink a six-pack...or two...then apply drunken retard strength :banana:
:cheers:
Posted 05 October 2009 - 05:17 PM
Yes! Superhuman drunken retard strength! That's just excellent. You guys had me laughing out loud.
Thank you both for your help. I was able to get the dust seal out after I realized that it wasn't just the rubber part and that it had a metal ring on it. I just wasn't seeing it for what it was, and I didn't have any good pictures or the replacement part to compare with. I thought the metal ring was part of the slider, not noticing the groove that separates the two. Ooops. Isn't my face red. Kenzo, you couldn't have said it better... "the dust seals removal is not very well explained". Yeah. Just a little.
Anyway, now I can see the snap ring that holds the oil seal in place. Can't seem to get that out now, but I've got a few tricks left up my sleeve. It's a tough one. Any tips?
Regardless, you guys got me a lot farther along than I was before I read your posts. Tonight I'll try to get that snap ring out and start "hammering". Good thing I've got a sixer in the fridge. :)
Thank you both for your help. I was able to get the dust seal out after I realized that it wasn't just the rubber part and that it had a metal ring on it. I just wasn't seeing it for what it was, and I didn't have any good pictures or the replacement part to compare with. I thought the metal ring was part of the slider, not noticing the groove that separates the two. Ooops. Isn't my face red. Kenzo, you couldn't have said it better... "the dust seals removal is not very well explained". Yeah. Just a little.
Anyway, now I can see the snap ring that holds the oil seal in place. Can't seem to get that out now, but I've got a few tricks left up my sleeve. It's a tough one. Any tips?
Regardless, you guys got me a lot farther along than I was before I read your posts. Tonight I'll try to get that snap ring out and start "hammering". Good thing I've got a sixer in the fridge. :)
Posted 05 October 2009 - 09:01 PM
Its best to look for the gap in the snap ring and I use a small screwdriver to pry on the part of the snap ring that curves inward for a bit closest to the gap in the snap ring and get one end of the snap ring out of the groove and work it around the rest of the ring until it pops out.
Some people like to "hammer" the forks apart which does allow you to check the bushings as well but if your just replacing the seals you can be careful not to scratch the fork tube and use a hook to get under the sealing surface of the fork seals and just pull them out. Then hammer in new seals in using a PVC tube sometimes pressing against the old seal resting on top of the new seal to prevent damage to the new seal. YMMV but it has worked great for me.
Some people like to "hammer" the forks apart which does allow you to check the bushings as well but if your just replacing the seals you can be careful not to scratch the fork tube and use a hook to get under the sealing surface of the fork seals and just pull them out. Then hammer in new seals in using a PVC tube sometimes pressing against the old seal resting on top of the new seal to prevent damage to the new seal. YMMV but it has worked great for me.
Posted 06 October 2009 - 06:34 AM
Hey all, thanks again for the help! I was able to get the snap ring out last night and the forks pulled apart with about two quick tugs. Now I've got access to the whole works and I can see some definate wear on my bushings. So, although it was the seals that were leaking, I'm glad to have it apart so I can replace those bushings, too. One of them is nearly 100% copper showing. Eeep!
Thanks again, everybody!
Thanks again, everybody!
Posted 06 October 2009 - 01:14 PM
Good going. Whenever I 've taken my forks apart to do the seals I notice a bit or quite a bit of copper showing on those bushes. I never worry about it thinking Honda are just being paranoid about maintenance.,,but replace them if you feel the need. Those bushes can be a pain to get back in on reassembly (least one side on one fork was for me) so we will maybe hear from you again before it's over. Good luck.
