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Motorcycle Forum / General / Yamaha / August 2005Yamaha Maxim fork removal
Greetings, all. PMFJIH, but I've got something I'd like to ask your advice on. I've got an '82 Yamaha XJ750 Maxim, with a blown fork seal, and I'm kinda wanting to try and see if I can do this myself. (Yes, I know, fools rushing in where angels fear to tread. How else am I supposed to learn to do this?) I've gone out and gotten the XJ CDs from the guy in Vermont, and printed out several web pages on the procedure. I have the seals, retaining clips, and dust caps. I've created the homemade tool that will help me undo the bolt at the bottom. I have several remaining questions, however. 1) Are the Maxim forks air pressurized? If so, where is the valve? 2) There is a dial with 1-4 and a philips screw at the top of each leg. Is that removed or loosened at the beginning of the procedure? 3) I'm still uncertain as to how to remove the forks in the first place. I see what looks like one clamp from the handlebars, and two others, one each at the top and bottom of the "triple tree", I think it's called. Are those the only things holding the forks on? 4) My reference material says 9.something ounces of fork oil. Is that total or per fork leg?  Signature-------------------------------------------------+------------------- "One World; One Web; One Program." -- Microsoft | OS/2 Warp | Solid like Linux "Ein Volk; Ein Reich; Ein Führer." -- Hitler | Easy like Windows -------------------------------------------------+------------------- Use your bandwidth. If you don't, it'll go stale. If Bill Gates had a dime for every time a Windows box crashed... oh, wait. He does. I Am Not A Number... Um...except for my TCP/IP address. If you can read this .sig, you're too damn close. Save a cow. Eat a vegetarian! Remember, EVIL spelled backwards is LIVE -- and we all want to do that! Dark Days in Human History: Hiroshima'45 Chernobyl'86 Windows'95 Proud member of the Signature is Longer Than The Post Association -------------------------------------------------------------------- > Greetings, all. > [quoted text clipped - 19 lines] > 4) My reference material says 9.something ounces of fork oil. Is > that total or per fork leg? I think you should buy a manual that describes the procedure... You seem to have a clue of what is going on, so you could just try taking things apart and see what happens. Some forks are trivial, some require special tools, some will kill you if ain't careful. Good luck, Bryan > I think you should buy a manual that describes the procedure... I've been looking for one locally, but nobody seems to have one onhand, and as I'd kinda like to get this done sooner rather than later, I'm not sure I want to wait to have it shipped. > You seem to > have a clue of what is going on, Thanks, but I'd tend to disagree -- I know enough to know that I don't know enough. Or to quote Shakespeare, "The fool doth think he is wise, but the wise man knows himself to be a fool". - ("As You Like It", Act V, Scene I) > so you could just try taking things apart > and see what happens. My big fear is that I won't be able to put it back together. :-( Signature------------------------------------------------+------------------ "One World, One Web, One Program." -- Microsoft | OS/2 Warp | Solid like Linux "Ein Volk, Ein Reich, Ein Fuehrer." -- Hitler | Easy like Windows ------------------------------------------------+------------------- "...but is what we're doing evil?" "Of course not! Listen, Zip -- EVIL spelled backwards is LIVE -- and we all want to do that!" Hi! I'm the Spawn of Satan (tm)! Ask me about franchise opportunities in your area! All your base are belong to us. Save a cow. Eat a vegetarian! Dark days in human history: Hiroshima'45 Chernobyl'86 Windows'95 Proud Member of the Signature Is Longer Than The Post Association -------------------------------------------------------------------- > Greetings, all. > [quoted text clipped - 11 lines] > > 1) Are the Maxim forks air pressurized? I believe so! is there a Shrader valve at the top of each fork, OR, possibly, an equalizer hose crossover connecting the forks, and a single valve on the right fork? > If so, where is the valve? Top right fork/ > 2) There is a dial with 1-4 and a philips screw at the top of each > leg. Is that removed or loosened at the beginning of the procedure? That is the FORK SPRING PRE-LOAD to 'dial-in' the ride firmness. Basically, a stepped ramp with four indents on the top of the spring. > 3) I'm still uncertain as to how to remove the forks in the first > place. I see what looks like one clamp from the handlebars, and two > others, one each at the top and bottom of the "triple tree", I think > it's called. Are those the only things holding the forks on? Yes. And the axle bolts, two up rfrom the bottom, that hold on the axle caps. > 4) My reference material says 9.something ounces of fork oil. Is > that total or per fork leg? The oil amount is per fork leg! Another IMPORTANT NOTE! The damping oil weight is also critical to rebound rate. And for the purposes of engineering (rebound rates, water moisture expulsion, thermal viscosity changes, and more), just use a quality fork oil from one of the listed on that table in that CDrom, or the book, or on the Web, here: http://home.att.net/~dirt.tech/susp-oil.htm And, the books is here? http://store.motolit.com/yamxj750four.html Schematic of forks for XJ750J model is here: http://houseofmotorcycles.bikebandit.com/partsbandit/oem_schematic_view~mp_id~~m scssid~QUUWMBSVUPWE9GP3SB3KERBN70V3D71A~schem_dept_id~633979~section_dept_id~1~s ection_dept_name~OEM+%28Stock%29+Parts~dept_type_id~2~model_dept_year~1982~model _dept_mfr~Yamaha~model_dept_id~632006~model_dept_name~XJ750J.asp Good luck! Signaturehttp://safeharbordome.com http://livecdlist.com http://distrowatch.com http://yolinux.com http://lugww.counter.li.org http://linuxiso.com Thanks for the help -- the patient will live, methinks. Found the Haynes manual locally; turns out what I thought was a clamp was in fact a cover for the Shrader valve (on the left side, not the right). Ended up having to use an impact wrench ("Say hello to my *little friend*!!") to get the blasted caps off, but hey -- that's what they're for, right? The homemade tool worked like a champ, cleaned out the lower fork legs with mineral spirits, pried out the old seals, hammered the new ones into position, bolted everything back together, added the fork oil, and away we go. Now all that remains is to remount the forks. Next project -- carbs! Signature------------------------------------------------+------------------ "One World, One Web, One Program." -- Microsoft | OS/2 Warp | Solid like Linux "Ein Volk, Ein Reich, Ein Fuehrer." -- Hitler | Easy like Windows ------------------------------------------------+------------------- "...but is what we're doing evil?" "Of course not! Listen, Zip -- EVIL spelled backwards is LIVE -- and we all want to do that!" Hi! I'm the Spawn of Satan (tm)! Ask me about franchise opportunities in your area! All your base are belong to us. Save a cow. Eat a vegetarian! Dark days in human history: Hiroshima'45 Chernobyl'86 Windows'95 Proud Member of the Signature Is Longer Than The Post Association -------------------------------------------------------------------- Evil Joe Schmuckatelli wrote: > Thanks for the help -- the patient will live, methinks. > [quoted text clipped - 10 lines] > > Now all that remains is to remount the forks. Next project -- carbs! Glad to have been of help! You will note that the Illustrated Parts Breakdown, plus, the schematics, for everything on your bike, including the carbs, is on the Internet at that link posted in my previous message. Signaturehttp://safeharbordome.com http://livecdlist.com http://distrowatch.com http://yolinux.com http://lugww.counter.li.org http://linuxiso.com >You will note that the Illustrated Parts Breakdown, plus, the schematics, >for everything on your bike, including the carbs, is on the Internet at >that link posted in my previous message. <nod> Those same illustrations (which came from microfiche, judging by the reaction of the parts department guy) are also on the XJ cds that I got from the guy in Vermont. I also found the same pics on the Yamaha site, and since they're much better quality, I'm saving them to my hard drive. :-) Thanks again. Signature-------------------------------------------------+------------------- "One World; One Web; One Program." -- Microsoft | OS/2 Warp | Solid like Linux "Ein Volk; Ein Reich; Ein Führer." -- Hitler | Easy like Windows -------------------------------------------------+------------------- Use your bandwidth. If you don't, it'll go stale. If Bill Gates had a dime for every time a Windows box crashed... oh, wait. He does. I Am Not A Number... Um...except for my TCP/IP address. If you can read this .sig, you're too damn close. Save a cow. Eat a vegetarian! Remember, EVIL spelled backwards is LIVE -- and we all want to do that! Dark Days in Human History: Hiroshima'45 Chernobyl'86 Windows'95 Proud member of the Signature is Longer Than The Post Association -------------------------------------------------------------------- I find the Yamaha Online parts http://www.yamaha-motor.com/sport/parts/home.aspx site very useful for listing XJ parts breakdown. If you still got questions post them at XJBikes.com and I'll get your the needed answers. SnoSheriff - www.XJBikes.com >>You will note that the Illustrated Parts Breakdown, plus, the schematics, >>for everything on your bike, including the carbs, is on the Internet at [quoted text clipped - 7 lines] > > Thanks again. |
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