Topic: I Messed Up fork - PLEASE HELP!

[bradweingartner]

The fork bottom isn't threaded, for clarification. Why the hell would there be a bolt just threaded into the bottom?! 

The fork bottom is just a hole, the peice on the other side is what it's bolted to. Drill off head with something close to 8-9mm. Everything will come apart appropriately.

As for the seal, those are in there TIGHT. Get a really big hook tool, hook onto the metal ring in the seal and yank like your life depends on it. If you try to PRY, you'll bugger up the body and risk gouging the seal surface on the fork. No fun.

Oh and make sure you took out the retaining clip. If the seal is really greasy you might miss the fact that it's held in by a big circlip.

[JerryRice]

Thanks Big Guy!

Phil. quick Q.. Do I really need a special tool to insert the new oil seals?? Or do you have a little trick I can use?

Thanks again for all of your help today.

[JerryRice]

Brad.. Holey Crap - Now I get it!
I thought the fork bottom was threaded. Now Phils post TOTALLY makes sense.. Just drill off the head!! Ahhhhh.

This makes life alot easier. Thanks guys for all of your help.

[phactory]

Jerry,

 Do a search on here for fork seal install. There is a 1 1/2 plastic PVC Pipe fitting that is available at any Home Depot that I used and it worked perfectly! Also get a couple of feet of 1 1/2 " pipe. I always put a bit of lithium grease on the od of the seal first, then slide the seal onto the fork tube and down to where it will be seated. Slide the fitting upside down onto the top of the seal, slide the plastic pipe on top of the bottom of the fitting and hit it with a soft mallet and it will seat perfectly. These directions will make a lot more sense when you have all of these parts in your hands.

Good luck, Phil

Thanks Big Guy!

Phil. quick Q.. Do I really need a special tool to insert the new oil seals?? Or do you have a little trick I can use?

Thanks again for all of your help today.

[JerryRice]

Once again, I would like to thank you very much. I was able to drill out the bolt tonight...it was amazing!

The PVC idea is genius Phil, I will do that!

[Joel]

Let me know how you get your seals out.  I'm still fighting with mine.

[Johnie]

Some guys will soak the seals in hot water and they come out easier that way.  I don't know, I got them out of my KO pretty easy with a screwdriver and was just very careful not to scratch the sleeve.

[JerryRice]

I am going to attempt seal removal tomorrow.

Phil, I would like the suspension on the stiffer side.
What kind of oil should I put in?

[joeyboy]

Ok, I thought I was a genius for tapering the end of a broom handle, rather than buy an impact wrench as advised by my local Honda dealer.  I quess I am a million in a million, lol.  It just works so good.  Originally I thought I did the same thing, I thought for sure I stripped the bolt and ruined my forks.  One thing I have learned while rebuilding my cb750 is that, just because things look bad, doesn't always mean they are, sometimes.

[phactory]

Jerry,

 I found this on the SOHC site. You can use 7.5 weight or 10 weight oil.

Fork fluid oil are as follows:

CB750 K0, K1, K2 Dry: 220-230cc (7.5 - 7.8 oz.) Fill after drain: 200-210cc (6.9 - 7.1 oz.).

CB750 K3, K4, K5, 76 Dry: 155-160cc (5.3 - 5.4 oz.) Fill after drain: 135-140cc (4.6 - 4.7 oz.).

CB750K-77 Dry: 155cc (5.3 oz.) Fill after drain: 145cc (4.9 oz.).

CB750K-78: 150cc (5.1 oz.) Note: Does not say dry or fill. My guess is: Fill after drain.

Phil

I am going to attempt seal removal tomorrow.

Phil, I would like the suspension on the stiffer side.
What kind of oil should I put in?

[JerryRice]

Phil, I hear people are using ATF or 10w-40. Can I do that? Is 20W-4o thicker?

[phactory]

I will admit to using 10W-40 in my forks right now. It actually said to use motor oil in the old maintenance manual I have (which I found on line here). I will see if I can dig it up and post the section on it.

pHil

Phil, I hear people are using ATF or 10w-40. Can I do that? Is 20W-4o thicker?

[JerryRice]

What would be the thickest oil i should put in?

Also I read this somewhere:

If your spring has sagged a bit, or you want stiffer springing, you can make a spacer out of a piece of 3/4" CPVC hot water plastic pipe. Just cut it to the length you want and put it on top of the spring, under the top fork bolt.

- Is that advisable?

[phactory]

From the original Honda 750 Workshop manual.

I don't know if they state a length for the fork spring, but I will look.

Phil

[phactory]

Measure the free length of the spring against these specs.

Phil

[JerryRice]

OMG - These fork seals are NOT coming out. I am ripping the dang rubber off peice by peice. I think its melted to the fork or something.

I am going to have to stick my rail between my legs on this one and take the
fork bottoms to a shop for removal.

[phactory]

Jerry,

 Huh? It CAN'T be that bad!! A little heat, a little penetrating oil, a little manhandling?? Can you post a pic of what is giving you so much trouble?

Phil

OMG - These fork seals are NOT coming out. I am ripping the dang rubber off peice by peice. I think its melted to the fork or something.

I am going to have to stick my rail between my legs on this one and take the
fork bottoms to a shop for removal.

[manjisann]

When I replaced my seals, I filled the fork up to the top with oil, stuck it in a pipe clamp and used pressure to pop the seal. You have to remove the circlip before doing this.

Here is an example of the clamp I am referring to.
http://www.rockler.com/product.cfm?page=17397&filter=30921&gclid=CJz-sNrGkJUCFQ0ziQodMnYAgQ&cookietest=1

You stick the fork in lengthwise, and start screwing the little clamp top down. If you have filled the fork, and get all the way to the bottom of the clamp, wait a minute and the pressure will force the seal out.

Hope this helps.

Brandon

[bradweingartner]

The fork seal should have a metal ring that gives it most of it's structure. Not the spring btw. You need a HOOK tool of some sort. Not a screwdriver or a prybar, those are totally inappropriate tools for this job


Ideally your hook will have a slid-hammer on the end of it... but that's just a bonus. Hook on to the metal and pull REAL hard.

[JerryRice]

bradweingartner, I went to a pals shop. he had that tool that you speak of. Ittook Alot of elbow grease but that tool did it!

[bradweingartner]

bradweingartner, I went to a pals shop. he had that tool that you speak of. Ittook Alot of elbow grease but that tool did it!

Glad to hear it bud! 

Nothing quite like having the right tool for the job.

[754]

Next time you get a set that bad, try this:

Drill 2 holes into the metal part of the seal,, around 1/16 inch or a bit bigger.....now find a block of wood, plastic or smooth aluminum that  is about 5/8 or 7/8 thick.

Now screw in two sheet metal screw into the drilled holes, make sure they do not touch the aluminum fork leg. Now using the shim above, use a claw hammer to pry up one side a bit, then the other.. a few of those and out she comes..

.cheapo puller


You think 750 forks are bad ,try early 70,s HD Kayabas, there is only about 4 mm of aluminum around the sides of the seal..