How NOT to Gixxerjasen your FJR forks

[raYzerman]

https://www.fjrforum.com/threads/fork-m ... 800/page-2

First the young fella deserves kudos for having the guts to tell us about it. Since then, a few others have managed the same feat, with various solutions. But bring it to light has helped the community, but the first time fork rebuilders sometimes don't do their homework and read about the solution I'm gonna tell you about.

It's all very simple as some of us know, particularly the tech day gurus, and y'all need to know and pass on the advice.......

I did not read through the whole thread above, so far I didn't see the preventative measure mentioned..... HEAT!!

The upper bushing on FJR's is the hardest one to remove of any bike I've ever worked on. Interference fit, pressed in there, and not helping is that seal that's also a beatch to remove. When rebuilding these forks, clamp them in a good vice horizontally, and remove the upper air/bug gut deflector by tapping it off with a piece of wood at the lower edge (you could warm it up a wee bit with a hair dryer or heat gun on low if you like).

Of course, you removed the dust seal and retaining ring, the cartridge, etc. and have the bare fork....... you are going to slide hammer the inner until everything pops out..... you know this already, BUT, without fail, Gen1 or 2 or 3 or 3+, heat the upper part of the lower fork tube with a propane torch until it is way too hot to touch... in the area of the upper bushing/seal.

Now slide hammer them apart, yes might take more than one shot, yes might jam the lower bushing into the middle one, may have to tap it back and go again. Maybe try not to have perfect alignment during slide hammering. HEAT is the key.

[gixxerjasen]

1. To avoid future issues, do not install the middle bushing. Most find that there's little benefit and suspension builders/repairers will leave them out. Traxxion left them out of mine.

2. Tip I was given, do not slide hammer them straight, put some angle on it a bit, that'll help keep that middle bushing from lining up with the upper bushing and merging and jamming.

[raYzerman]

Yep, no middle bushings..... really don't do anything useful. I don't put them in any more.

Had a couple of guys got theirs jammed.... both came up with the idea to put an axle in the lower and a clamp affair up top, then one used an engine hoist to get them apart. The other guy used his Kubota bucket to lift them apart. Minor scratch marks in the bore, but nobody gives a crap that high up (above the middle bushing line).

Then there's the FYB excellent method of removing the seals, don't really need heat.... fillerup with oil, but the fork cap back on and put it in yer hydraulic press.... I made one, works good actually... Bobby's is better.
Someone may be able to improve on my design... I have a drawing if yer interested.

[gixxerjasen]

I believe that's actually the Yamaha approved way of popping them out. I like that setup.

[wheatonFJR]

I'm just here because I like the name of this thread.