'85 Fork Seals, looking for, if memory serves, David R's homemade tool inst.

[JoBrCo]

Hello Fellow FJ'ers,

I need to replace my fork seals after a small accident.  She didn't know how to use her passenger side view mirror, or so it surely seemed, go figure?

Anyway, I seem to remember David R engineering some sort of home made tool to help in disassembly/reassembly (may have been on the yahoo site, memory fading fast ).

I have a small welder if needed to manufacture the tool, though I suck at welding, thank god I'm good at grinding, probably because I suck at welding.

I have a liter of Motul synthetic 10 wt and picked up a seal and wiper kit from Randy.  I've never done this before, but I believe I need a special tool to take the fork tubes apart, and that's all?  If not, please advise.

I'm also going to wire brush and clear coat the lowers while replacing the seals, any reccomendations on non yellowing, long lasting clear coat?).

While at it, I've picked up the All Balls head bearing kit from RPM as well. The original set is a little sloppy, I live in pot-hole city these days, (God I really miss those california roads of old, smooth as a babies bottom).  Any pointers?  I was thinking large washers, threaded rod and nuts for installation of the races. Removal?  Of course I'm very concerned with "squarely" doing such things.

So if anyone can point me in the right direction to the requirements, as well as any pointers, I'd really appreciate it.


FJ's forever 

JoBrCo

[FJ1100mjk]

For reference...

http://www.fjowners.com/index.php?topic=14227.0

[red]

Hello Fellow FJ'ers,

I need to replace my fork seals after a small accident.
JoBrCo

JoBrCo,

Sorry that you had a run-in with a dull one.  Hope it goes well for you.

Unless the seals are physically damaged, you may be able to clean them out where they are leaking.  You can make your own SealMate tool with scissors; just cut one out from a plastic milk jug.  You can Google for a picture of the SealMate, or buy a real one for ~US$5 at most cycle shops.  YouTube has "how-to" videos on the easy process.

Cheers,
Red

[JoBrCo]

FJ1100mjk: Thanks much for the link, George's tool looks great, but I wouldn't expect anything less from him.

RED:  Thanks!
And thank god the cop sited her.  I told her that it didn't matter how fast I came from behind her to enter the right lane, as long as it was under the speed limit, and that all that did matter, according to the law, is that one must ensure a lane is clear before entering it, yet she just didn't get it??  She actually initiated her lane change before using her turn signal!  And I don't think she used her mirror at all, becasue she would have seen me. I've been getting a lot of close calls these days, that I never saw back in the day before I mothballed her in 1995.  I think the quality of drivers these days, is sorely lacking, except for bikers of course.

Anyway, since her seals are the original '85 factory seals, she's got 39,000 miles on her, and all the other rubber is dryrotting quite nicely, I decided to just go ahead and replace them.  But your recommendation on the seal cleaner, shall surely be considered for the new seals.  Nothing I hate worse than going through all that work, just to have the new stuff leak shortly afterward. Yes that's my luck for you.  I got one of those Motion Pro 41mm seal drivers, so I expect it to be a good install. So I'm thinking remove the fork tube first then easily remove the old seal, yes?

Everyone: I need to gather all that I need for the job before I start, becasue the bike is the only transportation I have at the moment. And while I probably should, I really don't feel like walking for 3-4 miles, round trip, to the local Home Depot/AutoZone.

Does anyone know how long the extension should be?

How about the Allen head size for an '85 lower bolt? (I guess I can get this tidbit from the service manual)

Does anyone know of a step by step guide link for the '84-'85 with all specific requirements.  (I love this site, but hate it's search engine.) Last year, Monkey or someone mentioned how to use Google search for this site, but whoever it was lost me.

Thanks again guys!


FJ's forever 

JoBrCo

[red]

Last year, Monkey or someone mentioned how to use Google search for this site, but whoever it was lost me.
Thanks again guys!
JoBrCo

JoBrCo,

On the usual Google Search line, enter the words that you want to search for.  Then add a space, and . . .

SITE:http://www.fjowners.com

or maybe better, for the fork job, search just the Maintenance forum here . . .

SITE:http://www.fjowners.com/index.php?board=11.0

all on one line.  Google will search only this site, or even one forum only here, to find your search terms.

Cheers,
Red

[FJmonkey]

I noticed that you already have a seal driver so this is for the benefit of others that like to DIY tools. I borrowed a seal driver from Simi_Ed and later copied it to add to my FJ tool box. Made from 2" PVC pipe, I know it is longer than required and will cut it down when I get the exact size needed.

[movenon]

As the bike is your only set of wheels and all you want to is change the fork seals and dust covers. I am not sure you need to pull apart the fork tubes.  I think (from memory) you just pull the forks,  pry off the dust covers, and remove a retaining spring (small screw driver) and pry out the seals ? Reinstall the seals etc. I just tapped my seals back in (lightly) without any special driver.  They have been in for a while now and no leaks.

I replaced mine during a rebuild and modification of the dampener system.  I also had to replace one fork tube because of a "pit" in the finish.

The bottom Allen is 10mm I believe. I don't remember the length of the extensions. I just stacked a combo that worked. WAG , 16 inchs.
George

[racerrad8]

So I'm thinking remove the fork tube first then easily remove the old seal, yes?

No, just carefully pry out the old seals and install the new ones.

Also, do not skimp on seals, you will be doing them again before you know it.

You should only use the NOK brand seals which I offer; RPM FJ 41mm Fork Seal & Wiper Kit


Randy - RPM

George beat me by a little of a minute...

[FJmonkey]

+1 with Randy at RPM, many have reported problems with aftermarket seals leaking when new. I have only used OEM seals with zero issues.... The seals don't cost nearly as much as it takes in labor to change them.... Do it once, do it right...

[JoBrCo]

So I'm thinking remove the fork tube first then easily remove the old seal, yes?

No, just carefully pry out the old seals and install the new ones.

Also, do not skimp on seals, you will be doing them again before you know it.

You should only use the NOK brand seals which I offer; RPM FJ 41mm Fork Seal & Wiper Kit



Randy - RPM

George beat me by a little of a minute...

See my OP, I bought the ones I have from you, but then I believe I understand marketing, though I'm no salesman, you?  


FJ's Forever 

JoBrCo

[JoBrCo]

As the bike is your only set of wheels and all you want to is change the fork seals and dust covers. I am not sure you need to pull apart the fork tubes.  I think (from memory) you just pull the forks,  pry off the dust covers, and remove a retaining spring (small screw driver) and pry out the seals ? Reinstall the seals etc. I just tapped my seals back in (lightly) without any special driver.  They have been in for a while now and no leaks.

I replaced mine during a rebuild and modification of the dampener system.  I also had to replace one fork tube because of a "pit" in the finish.

The bottom Allen is 10mm I believe. I don't remember the length of the extensions. I just stacked a combo that worked. WAG , 16 inchs.
George

Thanks George that sounds a whole lot easier and less time consuming!  But if I do it that way will my very close inspection with a 10x coddington be able to ensure there are no pits on my tubes where it counts?

FJ's Forever   

JoBrCo

[JoBrCo]

I noticed that you already have a seal driver so this is for the benefit of others that like to DIY tools. I borrowed a seal driver from Simi_Ed and later copied it to add to my FJ tool box. Made from 2" PVC pipe, I know it is longer than required and will cut it down when I get the exact size needed.

Does that DWV PVC have enough mass?
It might be better to keep it long, more mass.

Plus I don't know about yours, but my wife said she likes mine real long.

FJ's Forever

JoBrCo

[movenon]

Don't over think it.
George

[FJmonkey]

Does that DWV PVC have enough mass?
It might be better to keep it long, more mass.

Plus I don't know about yours, but my wife said she likes mine real long.

FJ's Forever

JoBrCo

The mass comes from the hammer that drives it... nuff said... 

[JoBrCo]

Don't over think it.
George

I'm just saying that I fully understand your concern of pits on the tube, effectively resulting in the machining action of the seals sealing lip, thus causing early failure.  I was agreeing with you George, while at the same time sharing your concern, as it's one of mine.   So will I be able to see pits where I don't want pits, using your method?  I wasn't being rhetorical, I really wanted your thoughts on the matter.