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Fork seal / oil change help needed

Discussion in 'The Garage' started by C41n, Oct 8, 2013.

  1. C41n

    C41n XS400 Member

    I am trying to change the seals on my 82 maxim xs400.

    I have the front forks off, the caps removed, the oil drained. Trying to follow this walkthough:


    I cannot get the inner shaft out of the outside lower shaft in order to facilitate seal removal. Since a picture is worth a thousand words.


    How does the inner fork come out? Baring that, how do I get the seal out? I tried prying it out with screwdriver, but it just wont come.
  2. 16VGTIDave

    16VGTIDave XS400 Guru Top Contributor

    Have you removed the bolts at the bottom of the forks? 6mm hex if I remember correctly. It was installed with thread locker at the factory, and possibly if they have been apart since then. An impact driver or pneumatic impact gun should make short work of getting them loose.
  3. Yamaguy55

    Yamaguy55 XS400 Addict

    If that doesn't work, Motion Pro makes a tool that will hold the damper rod on the inside while you bust a gut breaking the Allen bolt loose. It should be a 6mm Allen. They're usually very tight, plus the factory goo-glue.
  4. C41n

    C41n XS400 Member

    I had not. I just got the first allen broke loose. Turned and turned and turned, and it is not coming out, nor is the tube. It sure seems like it is just spinning in place. Tried to turn the tube also but feel like I am just spinning my wheels here. Is there something else i am missing?
  5. C41n

    C41n XS400 Member

    I tried the other side, and after breaking loose the tube just came right out. Still I cannot get the first side to come completely unscrewed. It just turns. Any suggestions?
  6. XSLeo

    XSLeo XS400 Junkie

    The Allen bolt screws into the bottom of the damper. You need to hold the damper to remove the Allen bolts. They make special tools for this or you can make your own.
    You have one apart, look at the top of the damper. Some have a 12 point socket in the top. others have a round projection with flat sides.
    Find a nut that just fits the 12 point socket if the damper. Use two of these nuts. Thread them on a bolt. Lock the two nuts together. Put the bolt into a socket with some extensions so you can reach the damper. Some tape to hold the nut in the socket Now slide this down into the fork to engage the damper. Turn the Allen bolt out.
    On the round with flats get a piece of pipe that just fits on the round part. Use a big hammer to flatten the end of the pipe so it fits snuggly on the two flats. Insert into forks to engage the damper, turn Allen bolt.
    Some just use a wooden broom handle. Stand the broom handle up, slide the fork down over the broom handle. Have a helper pull the fork down firmly on the broom. Turn the Allen bolt. The down pressure on the broom will hold the damper.
    franticvike likes this.
  7. C41n

    C41n XS400 Member

    I don't have a lot of these things, nor a helper.. However you have given me some ideas. I am going to try again now. Thank you!
  8. C41n

    C41n XS400 Member

  9. Thanks for posting that "how to" link. I followed the instructions to do this today. Easy peasy.

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