Fork Seal replacement going wrong - Yamaha FJR Forum : Yamaha FJR Owners Forums
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post #1 of 4 (permalink) Old 09-18-2020, 03:26 PM Thread Starter
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Fork Seal replacement going wrong

Hi there fellow riders.
I purchased a 2012 FJR1300 with 7400 miles on it in late May, and at the time of purchase I had noticed that the right fork seal was l weeping oil a little. 2000 miles later and I'm trying to do my first fork seal replacement job and I've run into an issue.

I have the new seal loaded into the fork, and last night at 1am while I was trying to get it seated I noticed the fork tube bound up and won't move. I tried to get it to release for about an hour, including using a floor jack and some wood to try and push it loose to no avail.
Anyone got any tips on how to unbork this before I cause too much expensive damage?

Thanks in advance!
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post #2 of 4 (permalink) Old 09-18-2020, 03:35 PM
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Sorry, Cam, I haven't had mine apart yet...

That is a "Winter" project for me.

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post #3 of 4 (permalink) Old 09-18-2020, 11:58 PM
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Tonight I can't look at your pic....... I'm a little confused... you already have the new seal in and the forks jammed? Shoulda only happened while you were slide-hammering them apart... here's the deal.....

The middle bushing has to be unseated with the lower bushing while slide-hammering it apart. That part happens easily. The upper bushing is an interference fit like I haven't seen on other bikes, and is a bear to unseat (along with the old seal).... so you MUST (very highly recommended at least), heat the lower fork tube in the upper bushing area to expand it or help loosen the bond, then slide hammer it out.

What happens is the lower bushing being a smaller diameter can go inside the middle bushing and expand it to the point of jamming inside the tube.
Now what.... BIG RUBBER hammer and beat the fork tube back down or put it in a hydraulic press. All such that you won't damage the fork tube at the top end (thus the BIG RUBBER hammer). May have to repeat.....

So if you already have the new seal in, and if the lower bushing is now somehow got jammed in the middle bushing again (there should have been no reason to slide that tube back up, so that's the part I don't understand), you will have to beat the fork tube back.

There is a chance the middle and/or lower bushing is now damaged (by the lower bushing), and you should now repeat removal of the upper bushing and seal, replace whatever and re-assemble. You should be able to re-use the upper bushing and the seal.

I do all my fork work with the forks clamped horizontally in a good vice. Perfect alignment when slide-hammering contributes to all this jamming... try not to be perfectly lined up....... and don't worry, you ain't the only one......
It has been debated about leaving the middle bushing out as its function is questionable (Gen 1 never had one). I'll leave that up to you.

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post #4 of 4 (permalink) Old 09-19-2020, 12:01 PM
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Also before replacing a seal because of weeping try this tool. They do work.
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