[Scotty Brown]

Hi All,  Trying to renovate a 1978 Honda XL75 for the grandkids--Bought new fork seals and dust covers for replacement.  Have the forks out of the triple trees but having a devil of a time getting the fork separated from the slider.  Appears to be some kind of a threaded ring below the seal holding it.  Removed all the lock rings and washers to no avail. Also removed the lower bolt which holds the damper rod.  Appreciate any advice you can spare.  Thanks, Scotty

[High On Octane]

Typically, after you have the fork legs removed: remove the top cap if applicable and drain fluid.  Remove the dampening rod bolt from the bottom of the fork leg.  Use a screw driver to pry up old dust wiper.  There should be a snap ring on top of the oil seal that will need to be removed.  After the dampening rod fastening bolt and upper snap ring are removed, aggressively slide the the 2 halves of fork legs away from each other several times.  Essentially, you are using the guide bushing to drive out the old oil seal in a slide hammer fashion.  Hope this helps.

Scottie

[Scotty Brown]

Thanks for the info -- I'll give it a shot---Much appreciated==

[High On Octane]

Did you get those forks figured out Scotty?

[Scotty Brown]

Nope, still working on it.  Took it to a Honda dealer today for some advise but they won't work on anything older than 2000.  An older tech took a look and tried to find some info but couldn't.   Taking to a friend who works on older bikes tomorrow.  May have to use heat and a slide hammer or fill forks with solvent and use a press.  Damn strange.  I'll let you know the outcome.  If it went together it has to come apart,  Scotty

[Scotty Brown]

SUCCESS AT LAST --So easy if you know how--My friend had them apart and rebuilt in less than 30 minutes.  HERE'S HOW==Place the main fork tube sideways in a vise.  Pull the lower leg back against the spring as far as you can and let go.  Took about six or eight shots like that and the fork came apart.  Act's like a slingshot and so simple.  Remember those seals had been in that fork for forty years so were TIGHT.  Did a little clean up, oiled the new seals and the fork tube--tap, tap, tap with a drift- installed the washer and snap ring.  FINISHED !

[High On Octane]

Cool!  Good deal!  First I've heard of that trick.  Flag you got it figured out.

[Scotty Brown]

Last request on forks --Does anyone know how many cc's of fork oil it takes?

[Richard230]

While I have no idea what oil volume your XL takes, it has been my experience that most fork service manuals are more concerned with the depth of the oil between the top of the fork tube and the top of the oil level with the fork compressed and the springs not installed.  Typically, this distance will be between 5 and 6 inches for conventional male slider forks. I would recommend giving that a try.  I think the only thing that you need to be concerned with is that the air gap is large enough to prevent over-pressurizing the forks and blowing a seal when the forks are fully compressed. The recommended amount of oil is likely just an approximation to allow the correct air gap so that a more detailed measurement doesn't have to be made when servicing the forks.

Unlike modern forks, the design of those old style forks were not engineered by rocket scientists. 

[grumpyed]

My book says 110cc per leg.

[Scotty Brown]

Thanks to all for pertinent info.---This forum is the greatest--Will be re-assembling the mini over the next few days and will send pix's when back together.  Will be taking to Willow Springs for the AHRMA races April 27th to use as a pit bike.  Hope some of out members will be there and introduce themselves.--Scotty

[Scotty Brown]

Just about finished.  Forks working perfectly--bit of wiring to finish and minor adjustments and Willow pits await,  plus the grandkids are excited.  Thank you all for your input.

[Scotty Brown]

Why I put this bike together -- One picture makes it all worthwhile--

[Richard230]

Great job Scotty.  Looks like someone is having fun!   

[Bilgemaster]

I'm pretty sure you're the Best Grandad Ever.

[Richard230]

Just call me an easy tap when a granddaughter needs some cash while in college. 

[High On Octane]

That's awesome Scotty!  That smile says it all!

[mattsz]

Why I put this bike together -- One picture makes it all worthwhile--

Amen, brother!