How NOT to Gixxerjasen your FJR forks
Posted: Sat Feb 22, 2025 10:26 am
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.
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.
