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XJ PARTS CATALOG, SECTION K: STEERING/SUSPENSION

SECTION K:

--Front Suspension: Front suspension Overview.



FRONT SUSPENSION:

FORK TUBE PARTS OVERVIEW:

Your front suspension is called on to do a lot of different tasks, sometimes all at the same time: steering and braking are the two most critical ones that come to mind. Thus the proper operation and integrity of your front forks, and all their parts and pieces, is vital to the proper operation, handling, and safety of your bike. And worn front forks are the primary reason why your front tires wear out quickly, or in an uneven pattern.

Although your front forks are pretty simple devices....a spring, inside a fluid-filled tube, that serves to soak up road imperfections while maintaining positive-yet-smooth road feel and control....there are quite a few items that need attention and periodic replacement in order to get the proper lifetime and performance out of your system.

We offer a variety of OEM and aftermarket products and tools needed to properly maintain and service your forks and keep them firmly planted on the road beneath you.


NOTE: The process of rebuilding your forks seems mystical and difficult to many first-timers, mainly because all of the internal parts are normally hidden from view.....and thus the "fear of the unknown" takes over. The fork mechanisms on most of the XJ-series bikes are really pretty simple, and the entire process of removing your forks from the bike is more time-consuming and involved than the actual re-building procedure. HOWEVER, this is one procedure that we strongly recommend that you have a factory or aftermarket service manual at-the-ready, because there are certain diagrams, specifications, and various "tricks of the trade" that you'll want to know about and follow when doing fork surgery.

Forks on these bikes generally fall into one of two categories: simple and more-difficult. The simplest forks are the ones that are not encumbered by any additional "enhancements", such as air-assistance or anti-dive features. Here's the scorecard:


SIMPLE: XJ550 Maxim, XJ550 Seca, XJ650 Maxim and Midnight Maxim, XJ650RJ Seca, and XJ700 non-X.

SIMPLE-PLUS: due to the air-assist function, these forks have a few additional parts (mainly o-rings) that must be attended to, but again, these forks could just as easily fall under the "simple" category above: 1982-83 XJ650 Maxim, XJ650 Turbo, XJ700-X, XJ750-X, XJ750 Maxim and Midnight Maxim, and XJ1100 models.

INVOLVED: due to both their air-assist and anti-dive functions, these forks are the most difficult to work on.....mainly due to the addition of the anti-dive function, which introduces quite a few additional parts into the internal fork mechanism. You will definitely want a service manual handy while working on these forks, and pay very close attention to the order and orientation of all the small parts during dis-assembly: XJ750 Seca and XJ900RK Seca models.


The following discussion has some very good pointers, tips, and photographs that detail the fork rebuild process on a 1981 XJ650 Maxim model (one of the "simple" fork systems), and is a good point of reference to help you decide whether the task is something that you wish to attempt yourself or leave to a qualified shop. Many thanks to owner Gamuru for his excellent efforts in providing this material:

http://xjbikes.com/forums/index.php?threads/8355


And thanks to user Tabaka45 for his expose of the XJ700 fork system with this great visual review of the procedures needed for rebuilding these forks, which can be seen at:

http://www.xjbikes.com/forums/threads/fork-seals-85-xj700n-picture-heavy.78389/


A slightly more complicated type of forking system can be found on the XJ750 Seca and XJ900RK models, due to the use of the anti-dive system. An XJ750 Seca fork system goes under the knife, here:

http://xjbikes.com/forums/index.php?threads/18730

and

http://xjbikes.com/forums/index.php?threads/41895


and owner "Alive" also has two great image-documentaries in regards to these more "complicated" fork systems. This first one shows the XJ900 (with the anti-dive system) while the second link shows the guts on the later XJ900 models (without the anti-dive system). Note that these images can also be used as a guide for any model front forking system that use the lower bushing on the chrome fork tubes:

http://xjbikes.com/forums/index.php?threads/44997

and

http://xjbikes.com/forums/index.php?threads/4067


while this photo-journal details the secret, inner workings of the "anti-dive" units found on XJ750 Seca and XJ900RK Seca models:

http://xjbikes.com/forums/index.php?threads/1860


And finally, for all you XJ750 Seca owners, here's the secrets to that funny and unique "oil lock valve assembly" used only on these models, and the proper orientation of all of those special washers:

http://xjbikes.com/Forums/viewtopic/p=159288.html

and

http://xjbikes.com/forums/index.php?threads/41895


And these incredible 3-D renderings of the inner workings of a forking system gives a great visualization of the internal components (it is based on the 1982-83 XJ650 Maxim forks):



and

http://xjbikes.com/forums/index.php?threads/29616


While many people may simply need to replace the OIL SEAL, SEAL CLIP, AND DUST BOOT (sometimes called a DUST WIPER"), we also recommend that whenever you have your forks apart, that you also replace the upper CAP BOLT CIRCLIP or SNAP RING, the cap bolt O-RING or GASKET, the fork oil drain screw GASKET, the damper rod retaining bolt SEAL, and, on air-fork-equipped models, the AIR VALVE O-RINGS.


Replacing these items now, while the forks are apart, can help prevent leaks and problems from developing down the road.

On high-mileage bikes, you should also replace the metal slider bushings, taper spindles, and other items.


Almost all forks usually require the use of a DAMPER ROD RETAINING TOOL to hold the damper rod in place while the lower damper rod retaining screw (in the bottom of the lower fork tube) is being loosened or tighten; otherwise, the damper rod will spin and freely and make removal and installation difficult if not impossible.

While the basic servicing and rebuilding of your forks is not a specialized skill, it can be somewhat confusing and daunting to people who have never performed such a task before. Since the procedures vary (sometimes greatly) between the different model bikes, we can give no real instructions or recommendations besides this: refer to your factory or aftermarket service manual for the proper procedures and techniques, and if you don't already have such a manual, please purchase one!

And here’s a couple of other good tips for exceptional fork rebuilding success and performance:

http://www.motorcycleproject.com/text/stiction_tuning.html

and:

http://www.motorcycleproject.com/text/shucking.html


The general layout of your forks (some models have more or less pieces than others), from the very top of the UPPER (also called the inner or chrome) TUBE moving downwards, is as follows. Note that the items underlined are the ones that we strongly recommend replacing during a fork rebuild procedure.

- Top Cap (rubber or plastic)
- Snap Ring, sometimes called a Stopper Ring
- Cap Bolt
- O-Ring for cap bolt
- Spacer (if used)
- Upper Spring Seat (if used)
- Fork Spring
- Damper Rod, with a plastic piston ring in the head
- Damper Rod Rebound Spring
- Oil Lock Valve Assembly (XJ750 Seca)

The following items may need replacing on high-mileage or neglected (dirty oil) bikes, as these items wear quickly if the fork oil was not refreshed regularly and thus was allowed to accumulate grit and abrasive particles:

- Taper Spindle
- Metal Slide Bushing #2, a split-ring bushing on the bottom of the chrome tube, not used on all models.


Air-assisted front forks (1982-3 XJ650 Maxim and Turbo, all XJ750, XJ900RK, and XJ1100 models) also included some or all of the following parts. Note that the items underlined are the ones that we strongly recommend replacing during a fork rebuild procedure.

- Schrader Valve(s) and their protective screw-on Caps.
- O-Rings for the schrader valve(s)
- Air joints (used on XJ650 Turbo, 1982 XJ750 Maxim, XJ900RK, and XJ1100).
- Cushion Gasket for air joint
- O-Rings internal to the air joints.
- Air Hose that connects the air joints.
- O-Rings for the end fittings of the air joint connecting hose.
- Stopper Ring on models using air joints.


Additionally, all XJ650 and XJ750 Midnight Maxim models, and XJ1100 models, had upper tube covers, their related guides and associated gaskets.


The LOWER (outer) FORK TUBE is populated as follows. Note that the items underlined are the ones that we strongly recommend replacing during a fork rebuild or seal replacement procedure.

- Dust boot
- Oil Seal Clip
- Oil seal Washer (XJ750 Seca, XJ900)
- Oil Seal
- Oil seal Spacer (XJ750 Seca, XJ1100)
- Fluid drain plug and gasket
- Damper rod retaining bolt and gasket
- Fork Oil


The following item may need replacing on high-mileage or poorly-maintained bikes:

- Metal Slide Bushing #1, a split-ring metal bushing near the top of the lower tube, just below the oil seal.




Finally, as part of any fork system service you should take the time to check the fork tube alignment.....an often over-looked part of fork system maintenance:

FORK TUBE ALIGNMENT CHECKING:

One feature of front fork systems that is typically overlooked is assuring that the two fork tubes are properly aligned with each other........that they are precisely spaced apart from each other, and also exactly aligned with each other in their "rake angles", and not "twisted" in relation to each other. Hitting large objects or deep holes with the front wheel, dropping the bike, slight bending or fatigue of the steering crown or lower bracket, or any other sort of injuries can result in fork tubes that are not perfectly in synch with each other, and that can cause both annoying and dangerous steering, handling, and braking problems.

Therefore it will be worth your while to check your fork tube alignment periodically, especially after you've had them out for a rebuild.......this will be the most time-efficient opportunity you'll have for this procedure, since it requires removal of the front wheel, headlight, and other assorted front-end components.

Although the following step-by-step guide was written for BMW owners, the same techniques and guidelines will apply on your bike:

http://w6rec.com/duane/bmw/fork/title.html


If you choose not to go through the above process, you can perform the following "poor-man's" fork alignment techniques as described in the following sections:

http://xjbikes.com/forums/index.php?threads/16145

and

http://xjbikes.com/forums/index.php?threads/9323

and

http://www.motorcycleproject.com/text/stiction_tuning.html

and

http://www.xjbikes.com/forums/threads/dropped-bike-need-help.97887/#post-533302

and a good video:




Listed in the following sections you will find our complete list of fork tube rebuild and service parts, arranged BY BIKE MODEL. The description of what each individual fork component part is, and its characteristics, is first review immediately below, and then the list of items by model follows.




UPPER (INNER) FORK TUBES AND PARTS:

Chrome Inner Fork Tubes:

ift3) Reproduction UPPER (INNER) (chrome) FORK TUBE, exactly replaces bent or rusted and pitted original tubes. Beautiful hard-chrome plating will last as long as original.

All fork tubes are precision made from centerless ground, cold-rolled steel tubing, and are then machined to proper tolerances and specifications as original. All inner tubes will fit either the left or right side. Stock length tubes are listed below. Shorter or longer length tubes are available by special order, but are non-returnable or refundable, and must be inquired about directly with us specifying the length desired.


NOTE: Used upper (inner) chrome fork tubes should always be checked for straightness using V-blocks and a run-out gauge (a local machine shop should be able to do this for your inexpensively), or using a professional quality straight-edge, or roll the tubes along a known flat surface such as a 30" x 12" wide piece of 1/4" thick plate glass (you can buy a cheap piece of scrap plate glass at Home Depot, etc.). Regardless of what anyone tells you, do NOT attempt to straighten bent tubes; they must be replaced!


Also, you should carefully inspect these chrome tubes for RUSTING or PITS in the area where the fork tube slides through the lower fork tube seal area. If there is only very minor surface rusting in this area, it may be possible to polish it out; however, if the rust has pitted or eaten into or below the surface of the metal, then you will need replace the tubes, as pitting in this area will very quickly chew up any new oil seals, and you'll have leaking seals again in no time! A good image of the type of damage that you need to check for can be seen (one the 2nd page) over at:

http://xjbikes.com/forums/index.php?threads/42966



Inner Tube Gaiter Boots:

Although not originally used on any XJ-series bikes, these accordion-pleated thick rubber boots fit into the area between the bottom of the steering underbracket and the top of the lower (outer) fork boots, covering and protecting this area from damage, while providing an "old-school" or cafe-racer type look. They are retained to the chrome tube itself (at their top end) via spring clips, and to the top of the lower fork tube via metal screw-clamps.

For a great visual of how these boots appear when installed properly, see the images at:

http://xjbikes.com/forums/index.php?threads/16019



Inner Tube Top Cover/Cap:

The very top part of your fork tube is rubber or plastic cap, that serves to seal the chrome inner tube from dirt and moisture, as well as providing a decorative look.



Inner Fork Tube Cap Bolt Circlip, Snap Ring, or Stopper Ring:

These rings, located at the very top of the chrome legs, underneath the top Cap/Cover, are what hold all the rest of the internal goodies in. They are usually pretty corroded after years of inattention, and it is recommended that they be replaced during any fork renewal process. Be careful when removing these items, they are under spring pressure!



Inner Fork Tube Cap Bolts and Related:

This is the rather solid upper "plug" that retains the innards of the fork tube (the spring sits just below it). Some models may incorporate an o-ring onto this cap bolt; other use a gasket below it. Although these cap "bolts" normally don't wear out, their corresponding o-rings or gaskets should always be replaced. Some models with air-adjustable forks have the air valve threaded into this cap bolt, and the o-ring around that air valve should also be replaced during a fork service or rebuild. Always use a liberal coating of pure silicone grease (HCP1714 or HCP20861) when installed these o-rings onto their cap bolts.


Cap bolts that are retained via a circlip (all XJ550 models, all XJ650 models (except Turbo), and the XJ750 Seca models) should have the circlip replaced. All other models use a threaded cap bolt that screws into the top of the fork tube, and these threads inside the fork tube should be inspected carefully and cleaned up if signs of deterioration or rust, etc. are noted.


HINT #1: the area where the CAP BOLT seals (at the top of the inner fork tubes) is very susceptible to rust from water accumulation and migration into this area. Rust and pitting in this area will not allow the upper cap bolt o-ring or gasket to seal properly.....a real problem! BE SURE TO INSPECT THIS AREA THOROUGHLY WHEN YOUR TUBES ARE APART. For proper oil and air sealing abilities (on those models equipped with air-assisted forks), you want this area to be as perfectly smooth as is possible.

If there is only surface rust, you can polish it away on fork tubes that use non-threaded cap bolts (all XJ550 models, all XJ650 models (except Turbo), and the XJ750 Seca models) using either bristle-wire brush HCP10222 or HCP10223, or our HCP9955 cylinder hone, chucked into a drill, and then follow-up with some 600- and 800-grit FINISHING PAPERS (these items are listed further below in the FORK TOOLS section).

Models using threaded fork cap bolts (XJ650 Turbo, all XJ700 models, all XJ750 models, XJ900RK, and XJ1100 models), should use the butterfly brush HCP10223, chucked into a drill,on the threaded portions and finishing paper on the smooth area above the threads.

If there are DEEP PITS in this area on the non-threaded style fork tubes, you can try polishing them out using the above method; however, if they have eaten into or below the surface of the metal, then you will either need to "rebuild" the surface (using JB Weld or some type of gel Super Glue formula to fill in the depression, and then sanding and/or honing any "high spots" back down to level).


It's always a good idea to use a strong smear of pure silicone grease (HCP1714 or HCP20861) on the top edge of the cap bolts after they are installed; this will help to seal that area as much as possible from water migration into the fork tubes and contaminating the fork oil.


HINT #2: the surfaces where the DAMPER ROD PISTON RING seals (along the entire inner diameter of the inner fork tubes, below the top cap bolt) is also prone to rust from water absorption and accumulation in the fork oil (another great reason to change the fork oil regularly!). Rust and pitting in this area will not allow the damper rod upper plastic piston ring to seal properly.....another real problem! BE SURE TO INSPECT THIS AREA THOROUGHLY WHEN YOUR TUBES ARE APART (a strong flashlight and good eyes are needed, as it will be a "looking down the barrel of a rifle" type of view). For proper oil management abilities and thus fork function, you want this area to be as perfectly smooth as is possible.

If there is only minor surface rust, you might be able to polish it away using our HCP9255 cylinder hone with the 400-grit stones (listed further below in the FORK TOOLS section) attached to a long extension.

If there are PITS in this area, there is no real cure for them, and the fork tube should be replaced.



Inner Tube Fork Springs:

Top-quality aftermarket progressively wound FRONT FORK COIL SPRINGS don't just "restore" the performance to your front forks, they actually improve it over the original equipment. Spring and suspension technology has come a long way in the 30 years since the XJ model bikes were designed and built, and our line of performance front coil springs will not only get rid of the sags and "mush" in your front end, but will give your bike a crisper, more controllable and predictable ride and handling quality due to their superior design, engineering, and manufacturing.

Original coil springs are what are known as "dual rate springs"........they have one fixed spring rate until a certain level of compression is reached, and then a firmer, stiffer rate (stronger resistance to compression) takes over (soft, soft, soft, soft, boom! stiff, stiff, stiff.......).

Replacement springs are what are known as a "progressive rate springs".........meaning that as the load on them increases, they get progressively firmer (softest, softest, soft, less soft, firm, firmer, firmer, really firm), rather than the "all or nothing" transition that takes places with the stock springs. Progressive rate springs tends to give both a smoother, less harsh ride, as well as increasing the performance of the front suspension during enthusiastic driving and the suspension action that it creates.


One pair of front springs does both front forks. Please note that some models will require the use, re-use, modification of the original, or the fabrication of the front spring spacers (and some models do not require the use of spacers at all).

NOTE: the more tightly coiled area of your fork springs (whether original or aftermarket) should be towards the TOP of the fork tube.



Inner Fork Tube Spring Spacers, Rebound Springs, and Spring Seats:

Used along with the coils springs, these various pieces allow for the proper pre-load and spring placement within the upper fork tube. Note that not all models used spring spacers.



Inner Tube Metal Slider Bushings:

These split-ring bushings fit over into a recess at the bottom of the inner chrome tube, and along with the lower tube slider bushing, serves as a both a tube guide and absorbs the majority of the side loading of the inner tube as it passes through the lower tube. If the fork oil hasn't been changed regularly, grit and moisture in the oil eventually wear down these slides, and thus require their replacement.



Inner Fork Tube Damper Rod:

Called a "compression cylinder" in Yamaha-engineering-speak, this precisely machined tube manages the oil flow within the fork system via oil bleed holes and passages. The top "head" of this damper rod rides within a flanged area of the upper (inner) fork tube and is also the lower spring seat for the coil spring, while the bottom of this rod is internally-threaded and bolted to the bottom end of the lower (outer) fork tube----and thus this rod is what actually makes the mechanical connection and physically "joins together" the upper and lower fork tubes.

HINT: check your the damper rod for straightness using a run-out gauge or a straightedge (or the edge of a machine-cut piece of flat glass).

The damper rod head has a plastic split-ring "piston ring" that should be inspected and replaced during a fork rebuild.



Inner Fork Tube Taper Spindle:

This oddly-named part is actually a tapered metal bushing that surrounds the lower shaft of the damper rod. If your taper spindle shows signs of wear (flat spots, gouges, scoring, etc.) then it should be replaced.



Inner Fork Tube Air System Parts:

Air Joint O-Rings:

These rubber o-rings provide and air-tight seal among the various component pieces used in air-assisted fork systems. These seals and o-rings should always be replaced during a fork rebuild procedure. And always use a generous coating of pure silicone grease (HCP1714 or HCP20861) when installed these o-rings onto their cap bolts.



Air Inflation Valves and O-Rings:

NOTE: the top caps that are used on all of the air valves listed below are NOT the same as those used on tire valves, as the ones used on the fork air valves are much shorter.



Inner Fork Tube Retaining Hardware:

Your chrome fork tubes (properly called the "inner" fork tubes) are held to your bike via the upper and lower steering brackets. The upper bracket is called the "crown bracket" and your handlebars bolt to this bracket, while the lower bracket is called, quite logically, the under-bracket. The under-bracket has the large diameter stem that goes up through the steering neck tube (that is part of the frame), and within that tube are the steering Neck (or "Head") Bearings. This stem is then bolted to the crown bracket after it has emerged from the top side of the frame steering neck tube.

The inner fork tubes are located in round bores on both sides of the upper crown bracket and the lower under-bracket. These bore are "split" and via proper tightening of the special Cinch Bolts, the proper tension is applied to firmly locate the fork tubes to the rest of the bike.

HINTS:

a) there may be oxidation on the triple tree clamps so it might be necessary to clean the inner diameter of these upper and lower bracket clamp bores using a rotary tool with a brass wire brush wheel.

b) do NOT grease or lubricate the inner diameter of these upper and lower bracket clamp bores or put any anti-seize or other protective coatings inside these clamps, as such products will impair the effectiveness of their grip.



Crown Bracket Inner Fork Tube Retaining Hardware:

For the upper (crown) bracket, the various cinch bolts, washer, and nuts that retain the fork tube to this bracket.



Under-bracket Inner Fork Tube Retaining Hardware:

For the lower (under) bracket, the various cinch bolts, washer, and nuts that retain the fork tube to this bracket.



LOWER (OUTER) FORK TUBE PARTS:

Dust Wiper Seals:

ft1) OEM and aftermarket lower fork tube Dust Wiper Seals will stop grit and moisture from entering the lower tube cavity and chewing up the oil seals. These dust wiper seals are the things you see at the very top of the lower fork tube.



Oil Seals:

ft1) OEM and aftermarket lower fork tube Oil Seals will stop those leaks and restore the performance to your front suspension and braking system. We offer three different grades of seals to satisfy everyone's needs:

a) OEM original equipment double-lip rubber seals provide the same quality and life expectancy as the originals. Although these are not the least expensive seals, no one ever went wrong with using original manufacturer products. Oil seals come with the internal tension spring when they were originally equipped as such.

NOTE: all oil seals install with the sharp, tapered "point" of the oil seal internal wiper lips pointing "down", so that these lips can wipe the oil from the chrome tube as it exits the lower tube.

b) Standard grade aftermarket double-lip BLACK OIL SEALS are the same or better quality than the OEM seals, but normally at a better price.

c) Premium grade aftermarket seals are a significant development in fork seal technology and feature a specially designed lip and spring tensions that result in a much lower sliding friction between the seal and the fork tube. Lower friction prevents un-wanted fork movement resistance from occurring, for instance, when initially entering a corner, or braking. Ideally, you want the inner forks to move smoothly and without any "choppiness" past the lower tube seal, rather than a "starting and stopping" motion due to tube-to-seal "stiction". These seals deliver the lowest possible friction coefficient of any of our seals, and are well worth the extra cost!


HINT: the areas in the lower fork tube where the OIL SEAL and the SLIDER BUSHING are located (at the top of the lower fork tubes) should be inspected carefully after dis-assembly and seal/bushing removal for any nicks, gouges, or imperfections. For proper oil seal slider bushing seating and fitment, you want this area to be as perfectly smooth as is possible.

It is recommended that you polish these areas using some 200-, 400-, 600-, and 800-grit FINISHING PAPERS.


ALSO---it's never a bad idea to use some of the 100% Silicone Grease as an "assembly lube" when installing any of these oil seals:

HCP1714 Aftermarket o-ring and gasket installation pure SILICONE GREASE:
$ 7.95

NOTE: the following product can only be shipped via ground transport (which thus eliminates the Priority Mail level of service for this item) and cannot (and will not----don't even ask!) be shipped outside of the continental USA. Therefore it may have to be shipped in a separate package from the remainder of your order, and will thus incur additional shipping charges.

HCP20861 Aftermarket industrial-strength SILICONE LUBE, in a large 16-ounce aerosol can. Concentrated silicone sprays on wet, and then dries to a super-slick, clear, non-greasy, non-staining finish. Resists moisture, stops squeeks, prevents binding on all types of surfaces (wood, metal, plastic, rubber, even fabrics). Won't wash away, protect against rust and corrosion, stable from -100 degrees up to 500-F. This fluid is also a great choice for use as installation lubricant for o-rings, oil seals, etc. (similar to our HCP1714 silicone grease paste) or wherever petroleum-based lubricants are not recommended.
$ 21.95


c) If needed, in addition to all of the above, you can gently heat (heat gun or even a 1500W hair dryer) the area of the fork tube where the seal fits.....this will expand that area a tiny bit, enough to make seal install a bit easier.

d) make sure you drive the seal in with a proper seal driver, or one that is fabricated correctly to push ONLY on the seal.....a proper sized OD flat washer can be a big help in this regard. The seal needs to be driven fully in place so that it "bottoms out" against the flat ledge in the fork tube......otherwise, it will be extremely difficult (if not impossible) to re-install the seal retaining clips.

Although fork seals can be installed without removing the inner chrome fork tube from the lower tubes, the proper procedure is to dis-assemble the forks completely, removing the inner tube from the lower tube. Trying to remove the oil seal from the lower tube while the inner tube is still installed risks damaging the lower tube, since it is very difficult to remove the old oil seals from the lower tube while the chrome upper tube is still in place.

Here is a good video on the entire process:





Oil Seal Retaining Clips:

These C-shaped metal clips retain the lower tube Oil Seals and should be replaced along with the oil seals.



Lower Tube Metal Slider Bushings:

These split-ring bushings press into the lower tube, below the oil seal, and serves as a both a tube guide and absorbs the majority of the side loading of the inner tube as it passes through the lower tube. If the fork oil hasn't been changed regularly, grit and moisture in the oil eventually wear down these slides, which have a teflon-like coating on their inner bearing surface to eliminate resistance.



Lower Fork Tube Oil Drain Screw and Gasket:

These small phillips-head screws, near the bottom of the lower tubes, allows you to drain the tubes prior to doing an oil change, or before tube removal and dis-assembly for seal replacement or other service work. The gasket that goes behind this screw should always be replaced in order to prevent oil leaks.

HINT: this gasket has a very small, very fine recessed area around its inner diameter on one side only..........and that side fits against the bottom of the drain screw. The perfectly flat side of the gasket goes against the fork tube drain port opening. We suggest that all pressure be taken off of the front forks (put the bike on its centerstand, and lift the front wheels off the ground) before you open the drain screw); otherwise, pressurized oil can squirt out at a significant rate and force!



Lower Fork Tube Damper Rod Retaining Bolt and Gasket:

These large socket-head cap screws, on the very bottom of the lower tubes, retains the inner tube damper rods to the lower tubes, and must be removed before the chrome inner tube can be separated from the lower tube for dis-assembly for seal replacement or other service work.

This screw is held in tight!----but it must be removed in order to take the fork upper and lower tubes apart in order to replace the lower tube seals, or any other internal parts.

The gasket that goes under this bolt should always be replaced in order to prevent oil leaks. These bolts, when re-installed, should be treated with a low-strength thread-locking compound.


The HCP4402 Damper Rod Retaining Tool, listed further below in the "Fork Tools" section of parts, is needed on some models to hold the damper rod itself (to prevent it from spinning freely) while this damper rod retaining screw is loosened and removed.



Lower Fork Tube Axle Retaining Hardware:

A variety of fasteners were used to cinch the front axle shaft to the lower fork tubes. Note that models with the front axle in a leading position to the fork tubes only used one retaining bolt (on the right side lower fork tube), while models with the front axle along the lower fork tube centerline (BELOW the fork tubes) used two retaining bolts (one on each lower fork tube).

SECTION K:

STEERING/SUSPENSION:

--Front Suspension: Forks, seals, springs, hardware, etc.


FORK TUBE REBUILD PARTS BY BIKE MODEL:

XJ550 MODELS FORK TUBE PARTS:

NOTE: items marked below in red are the parts typically needed when doing a basic fork system rebuild.

A good visual review of the procedures needed for rebuilding these forks can be seen at:

http://xjbikes.com/forums/index.php?threads/8355

And these incredible 3-D renderings of the inner workings of a forking system gives a great visualization of the internal components (it is based on the 1982-83 XJ650 Maxim forks):



and

http://xjbikes.com/forums/index.php?threads/29616


XJ550 Maxim and XJ600 Seca II owners may also wish to note the procedure needed to separate the inner tubes from the lower tubes (the "battering ram" procedure) since these forks also use the slider bushings on the bottom of the chrome tubes as shown on these XJ900 forks:

http://xjbikes.com/forums/index.php?threads/4067


FORK TUBE REBUILD PARTS KITS:

We now offer both a BASIC FORK REBUILD KIT and PERFORMANCE FOR TUBE REBUILD KITS so that you can get all the typically-needed rebuild parts under one simple part number. Each kit is specifically assembled and correct for your particular model bike.

Basic fork rebuild kit contains at least the following items:
- cap bolt o-rings.
- cap bolt retaining rings.
- standard quality lower fork tube oil seals.
- oil seal retaining clips.
- oil drain screws and gaskets.
- damper rod bolts and crush washers.
- damper rod head piston rings

HCP20611 Aftermarket fork tubes BASIC FORK REBUILD KIT. For all XJ550 Maxim, 1980-81 XJ650 Maxim and Midnight Maxim models, 1982 XJ650RJ Seca, and XJ650 Euro models. One kit does both front tubes.
$ 74.95

HCP20603 Aftermarket fork tubes BASIC FORK REBUILD KIT. For all XJ550 Seca models. One kit does both front tubes.
$ 89.95


Performance fork rebuild kit contain all of the basic rebuild kit components, along with:
- performance fork springs (and related springs seats and pre-cut spring spacers in the XJ550 Maxim kit).
- upgraded, high-performance lower fork tube oil seals.
- lower fork tube dust boots.

HCP20602 Aftermarket fork tubes PERFORMANCE FORK REBUILD KIT. For all XJ550 Maxim models. One kit does both front tubes.
$ 289.95

HCP20604 Aftermarket fork tubes PERFORMANCE FORK REBUILD KIT. For all XJ550 Seca models. One kit does both front tubes.
$ 229.95


Of course, all of the component pieces can be ordered as individual pieces from the selections listed below, as well as non-typical wear items (inner tubes, damper rod piston rings, taper spindles, cap bolts, etc.), as well as the fork oil and specialty tools needed to properly restore or enhance your front suspension performance.



UPPER (INNER) FORK TUBES AND PARTS:

Chrome Inner Fork Tubes:

HCP8522 Aftermarket chrome INNER FORK TUBE, fits left or right side, for all XJ550 Maxim models, each:
$ 299.95

HCP8522SET2 Aftermarket chrome INNER FORK TUBES, set of 2:
$ 489.95



HCP8523 Aftermarket chrome INNER FORK TUBE, fits left or right side, for all 1981-1983 XJ550 Seca models. NOTE: these tubes use a circlip-retained upper cap bolt (HCP8255); some models may have used threaded upper cap bolt, in which case you should order the HCP8524 fork tubes listed below. Please verify which style you have before ordering! Each:
$ 299.95

HCP8523SET2 Aftermarket chrome INNER FORK TUBES, set of 2:
$ 489.95



HCP8524 Aftermarket chrome INNER FORK TUBE, fits left or right side, for all 1981-83 XJ550 Seca models. NOTE: these tubes use a threaded upper cap bolt; most models used the circlip-retained cap bolt fork tubes HCP8523 listed above. Please verify which style you have before ordering! Each:
$ 299.95

HCP8524SET2 Aftermarket chrome INNER FORK TUBES, set of 2:
$ 489.95



Inner Tube Gaiter Boots:

Although not originally used on any XJ-series bikes, these accordion-pleated thick rubber boots fit into the area between the bottom of the steering underbracket and the top of the lower (outer) fork boots, covering and protecting this area from damage, while providing an "old-school" or cafe-racer type look. They are retained to the chrome tube itself (at their top end) via spring clips, and to the top of the lower fork tube via metal screw-clamps.

For a great visual of how these boots appear when installed properly, see the images at:

http://xjbikes.com/forums/index.php?threads/16019


HCP10806 Aftermarket front fork tube GAITER BOOT, black pleated rubber boot is the correct length and diameter to fit all of the following models: all XJ550 models, all XJ650 models, and all XJ750 Maxim and Midnight Maxim models. Does not include attaching hardware. Heavy-duty design has equal spacing between each accordion pleat. Each:
$ 79.95

HCP10806SET2 Aftermarket front fork tube GAITER BOOTS, set of 2:
$ 149.95



HCP10941 Aftermarket front fork tube GAITER BOOTS, black pleated rubber boot is the correct length and diameter to fit all of the following models: all XJ550 models, all XJ650 models, and all XJ750 Maxim and Midnight Maxim models, all 1981-83 XJ750 Seca, XJ750 Euro, XJ1100, and XS1100 Special and Midnight Special models. Does not include attaching hardware. Light-duty design has equal spacing between each accordion pleat. Pair:
$ 29.95

HCP10942 Aftermarket front fork tube GAITER BOOTS, royal blue pleated rubber boot is the correct length and diameter to fit all of the following models: all XJ550 models, all XJ650 models, and all XJ750 Maxim and Midnight Maxim models, all 1981-83 XJ750 Seca, XJ750 Euro, XJ1100, and XS1100 Special and Midnight Special models. Does not include attaching hardware. Light-duty design has equal spacing between each accordion pleat. Pair:
$ 29.95

HCP10943 Aftermarket front fork tube GAITER BOOTS, red pleated rubber boot is the correct length and diameter to fit all of the following models: all XJ550 models, all XJ650 models, and all XJ750 Maxim and Midnight Maxim models, all 1981-83 XJ750 Seca, XJ750 Euro, XJ1100, and XS1100 Special and Midnight Special models. Does not include attaching hardware. Light-duty design has equal spacing between each accordion pleat. Pair:
$ 29.95



HCP10938 Aftermarket front fork tube GAITER BOOTS, black pleated rubber boot is the correct length and diameter to fit all of the following models: all XJ550 models, all XJ650 models, and all XJ750 Maxim and Midnight Maxim models, all 1981-83 XJ750 Seca, XJ750 Euro, XJ1100, and XS1100 Special and Midnight Special models. Does not include attaching hardware. Light-duty design has equal spacing between each accordion pleat, and each bellows gets wider as the boot extends from top to bottom. Pair:
$ 29.95

HCP10939 Aftermarket front fork tube GAITER BOOTS, royal blue pleated rubber boot is the correct length and diameter to fit all of the following models: all XJ550 models, all XJ650 models, and all XJ750 Maxim and Midnight Maxim models, all 1981-83 XJ750 Seca, XJ750 Euro, XJ1100, and XS1100 Special and Midnight Special models. Does not include attaching hardware. Light-duty design has equal spacing between each accordion pleat, and each bellows gets wider as the boot extends from top to bottom. Pair:
$ 29.95



HCP11420 Aftermarket fork tube gaiter boot LOWER RETAINING SPRING-CLAMP. Black powdercoated wire-spring type clamp has that old-time look and feel to it. Secure the lower end of the gaiter boot to the top of the lower (outer) fork tube. Fits all XJ-series models. Use 1 per tube, each:
$ 9.95


NOTE: gaiter boots normally do not require any type of retainer at their upper end, as the tight friction fit between the boot opening and the chrome tube prevents migration of the boot. If movement seems to occur, then we recommend the use of thin, black electrical wire ties to cinch the boot flange tightly to the tube.



Inner Tube Top Cover/Cap:

HCP8252 OEM inner fork tube black rubber top CAP, fits either the left or right side tube of the following models: XJ550 all, all XJ650 Euro models, 1980-81 XJ650 Maxim and Midnight Maxim, the 1982 XJ650RJ Seca, and 1981 XJ750 Seca models. Each:
$ discontinued

HCP22882 Aftermarket inner fork tube black rubber top CAP, fits either the left or right side tube of the following models: XJ550 all, all XJ650 Euro models, 1980-81 XJ650 Maxim and Midnight Maxim, the 1982 XJ650RJ Seca, and 1981 XJ750 Seca models. Each:
$ 19.95



Inner Fork Tube Cap Bolts and Related Hardware:

HCP8255 OEM inner fork tube CAP BOLT, fits either side. Used on all XJ550 models with circlip-retained cap bolts, all XJ650 Euro models, 1980-81 XJ650 Maxim and Midnight Maxim, and 1982 XJ650RJ Seca models. Each:
$ 49.95

HCP2323 OEM inner fork tube top cap bolt RETAINING RING, fits either the left or right side tube of the following models: all XJ550 models, all XJ650 Euro models, XJ650 Maxim, Midnight Maxim, and XJ650RJ Seca models, and 1981 XJ750 Seca models. Each:
$ 8.95

HCP20715 Aftermarket inner fork tube top cap bolt RETAINING RING, fits either the left or right side tube of the following models: all XJ550 models, all XJ650 Euro models, XJ650 Maxim, Midnight Maxim, and XJ650RJ Seca models, and 1981 XJ750 Seca models. Each:
$ 5.95


HCP2324 OEM inner fork tube CAP BOLT O-RING, fits either side. Used on all XJ550 models, all XJ650 Euro models, XJ650 Maxim and Midnight Maxim, and 1982 XJ650RJ Seca models. Each:
$ 5.95

HCP20699 Aftermarket inner fork tube CAP BOLT O-RING, fits either side. Used on all XJ550 models, all XJ650 Euro models, XJ650 Maxim and Midnight Maxim, and 1982 XJ650RJ Seca models. Each:
$ 3.95



Inner Tube Fork Springs:

HCP9434 Aftermarket front suspension COIL SPRINGS, one pair does both forks. For all XJ550 Seca models. Front spring spacers are not required with these springs. NOTE: due to the difference in size of this spring versus stock springs, you will need to use approximately 4 cc's more fork oil (for a total of 234cc's per tube) when installing these springs. NOTE: springs should be installed with the tighter (more-closely spaced together) coils towards the top of the fork tube.
$ 119.95


HCP9433 Aftermarket front suspension COIL SPRINGS, one pair does both forks. For all XJ550 Maxim models. Front spring spacers are not included with these springs, and you will need the installation of an HCP8239 spring seat (one for each spring) and the fabrication of a 31.50mm long spacer when replacing stock springs. You can use the HCP8284 spring spacer tube (stock for 1982-83 XJ650 Maxim models) and cut it down to the proper length; one tube will provide enough material to do both springs and fork tubes…..or you can order the HCP21018 spacers tubes which are already cut to the correct length. NOTE: due to the difference in size of this spring versus stock springs, you will need to use approximately 13 cc's more fork oil (for a total of 285cc's per tube) when installing these springs and using the stock thin-wall metal spacer tubes as recommended above. The use of other type of spacers (thick-wall PVC pipe, for instance) will change this recommended fork oil volume by an unknown amount. NOTE: springs should be installed with the tighter (more-closely spaced together) coils towards the top of the fork tube.
$ 119.95


HCP8239 OEM inner fork tube SPRING SEAT, fits either side. Use on all XJ550 Maxim models when installing the HCP9433 replacement springs above. Each:
$ 12.95

HCP20994 Aftermarket inner fork tube SPRING SEAT, fits either side. Use on all XJ550 Maxim models when installing the HCP9433 replacement springs above. Each:
$ 10.95


HCP8284 OEM inner fork tube SPRING SPACER TUBE, fits either side. Use on all XJ550 Maxim models when installing the HCP9433 replacement springs above. One spacer tube will provide enough material to do both springs.
$ 14.95

HCP21018 Aftermarket inner fork tube SPRING SPACER TUBE, fits either side. Use on all XJ550 Maxim models when installing the HCP9433 replacement springs above. Each spacer tube is pre-cut to the correct length for use with the HCP9433 springs; use 1 spacer per tube.
$ 16.95

HCP21018SET2 Aftermarket inner fork tube SPRING SPACER TUBE, fits either side. Set of 2 spacers:
$ 29.95



Inner Fork Tube Spring Spacers, Rebound Springs, Damper Rods, and Spring Seats:

HCP8253 OEM inner fork tube damper rod REBOUND SPRING, fits either side. Used on all XJ550 models, all XJ650 models (except Turbo), and 1983 XJ750 Maxim and Midnight Maxims. Use 1 per tube, each:
$ 24.95


HCP13656 Aftermarket inner fork tube damper rod PISTON RING, fits either side. Used on all XJ550, XJ650, all XJ750 (except XJ750 Seca and XJ750-X models), and 1978-79 XS1100 Standard models. Use 1 per fork tube. Each:
$ 11.95




Inner Fork Tube Taper Spindle:

HCP3085 OEM upper (inner) fork tube TAPER SPINDLE, fits either side. Fits all XJ550 models, 1984 FJ600, all XJ650 models, all XJ700 and XJ750-X models, all XJ750 Maxim and Midnight Maxim models, XJ900 N/FN and F models, and all XS1100 Standard models. Each:
$ 16.95



Inner Tube Metal Slider Bushings:

HCP10702C Aftermarket inner fork tube METAL SLIDER BUSHING, fits either left or right tube on the following models: all XJ550 Maxim and 1982 XJ650 Turbo models. One slider does one tube. Each:
$ 39.95

HCP10702CSET2 Aftermarket inner fork tube METAL SLIDER BUSHINGS, set of 2:
$ 74.95



INNER FORK TUBE RETAINING HARDWARE:

Crown Bracket Inner Fork Tube Retaining Hardware:

HCP4529 OEM crown bracket fork tube CINCH BOLT, alloy steel, hex-head bolt with a bright finish, use 1 per side. For the following models: all XJ550, 1980 XJ650 Maxim, and 1979 XS1100 Special models. Each:
$ 2.95

HCP21973 Aftermarket crown bracket fork tube CINCH BOLT, alloy steel, hex-head bolt with a bright yellow-zinc finish, use 1 per side. For the following models: all XJ550, 1980 XJ650 Maxim, and 1979 XS1100 Special models. Each:
$ 1.95

HCP21974 Aftermarket crown bracket fork tube CINCH BOLT, alloy steel, hex-head bolt with a black finish, use 1 per side. For the following models: all XJ550, 1980 XJ650 Maxim, and 1979 XS1100 Special models. Each:
$ 1.95

HCP21975 Aftermarket crown bracket fork tube CINCH BOLT, 18/8 stainless steel, hex-head bolt with a bright finish, use 1 per side. For the following models: all XJ550, 1980 XJ650 Maxim, and 1979 XS1100 Special models. Each:
$ 3.95



HCP4960 OEM under-bracket fork tube CINCH BOLT, alloy steel, socket head cap screw with a bright finish. Use 2 per side on all 1981-83 XJ550 Seca models, and 1 per side on all 1984-85 FJ600 models. This bolt also secures the horn bracket to the under-bracket. Each:
$ discontinued

HCP21945 Aftermarket under-bracket fork tube CINCH BOLT, alloy steel, socket head cap screw with a bright finish. Unlike the original fastener, this bolt does not have a captive lock-washer, and a separate lock-washer should be used. Use 2 per side on all 1981-83 XJ550 Seca models, and 1 per side on all 1984-85 FJ600 models. This bolt also secures the horn bracket to the under-bracket. Each:
$ 4.95

HCP21946 Aftermarket under-bracket fork tube cinch bolt LOCK WASHER, zinc-plated alloy steel with a bright finish. Use 1 per bolt on all 1981-83 XJ550 Seca and 1984-85 FJ600 models. Each:
$ 1.25

HCP21947 Aftermarket under-bracket fork tube cinch bolt LOCK WASHER, 18/8 stainless steel with a bright finish. Use 1 per bolt on all 1981-83 XJ550 Seca and 1984-85 FJ600 models. Each:
$ 1.25

HCP21948 Aftermarket under-bracket fork tube cinch bolt LOCK WASHER, black oxide-coated alloy steel. Use 1 per bolt on all 1981-83 XJ550 Seca and 1984-85 FJ600 models. Each:
$ 1.25



HCP2537 OEM crown bracket fork tube FLAT WASHER, alloy steel, bright finish. Use 2 per side. For the following models: all XJ550 models, 1980 XJ650 models, and all XJ700 models. Each:
$ 1.95

HCP26192 Aftermarket crown bracket fork tube FLAT WASHER, alloy steel, bright finish. Use 2 per side. For the following models: all XJ550 models, 1980 XJ650 models, and all XJ700 models. Each:
$ 0.95

HCP26193 Aftermarket crown bracket fork tube FLAT WASHER, 18/8 stainless steel, bright finish. Use 2 per side. For the following models: all XJ550 models, 1980 XJ650 models, and all XJ700 models. Each:
$ 1.25

HCP17110 Aftermarket crown bracket fork tube FLAT WASHER, 316 stainless steel, dull finish. Use 2 per side. For the following models: all XJ550 models, 1980 XJ650 models, and all XJ700 models. Each:
$ 1.95

HCP26189 Aftermarket crown bracket fork tube FLAT WASHER, alloy steel, black finish. Use 2 per side. For the following models: all XJ550 models, 1980 XJ650 models, and all XJ700 models. Each:
$ 2.95



HCP4528 OEM crown bracket fork tube CROWN NUT, alloy steel, bright finish. For the following models: use 1 per fork tube (2 per bike) on all XJ550, 1980 XJ650 Maxim, and 1979-1980 XS1100 Special models. Use 1 per tube cinch bolt and 1 on the rear lateral stem pinch bolt (total of 3 per bike) on all 1978-80 XS1100 Standard models. Each:
$ 3.95

HCP10959 Aftermarket crown bracket fork tube cinch bolt CROWN NUT, alloy steel, bright finish, same height as the HCP4240 and HCP4528 crown nuts. Each:
$ 2.95

HCP21940 Aftermarket crown bracket fork tube cinch bolt CROWN NUT, 18/8 stainless steel, bright finish. The rounded dome head is slightly taller (3mm) than the originals. Each:
$ 3.95

HCP21941 Aftermarket crown bracket fork tube cinch bolt CROWN NUT, chromed steel, bright finish. The rounded dome head is slightly taller (3mm) than the originals. Each:
$ 6.95



HCP18011 Aftermarket cinch bolt head protective CAP. Smooth, black plastic cap snaps over the head of the fork tube cinch bolts, giving them a very "modern" look, protecting the head from rust. Fits all OEM or aftermarket bolts with a 12mm hex or socket head. Each:
$ 3.95



Under-bracket Inner Fork Tube Retaining Hardware:

HCP3652 OEM under-bracket fork tube CINCH BOLT, use 2 per side. For the following models: all XJ550 models, all XJ650 models, XJ750-D, all 1982-83 XJ750 Maxim models, and XJ900 N/FN and F models. Each:
$ 9.50


HCP18011 Aftermarket cinch bolt head protective CAP. Smooth, black plastic cap snaps over the head of the fork tube cinch bolts, giving them a very "modern" look, protecting the head from rust. Fits all OEM or aftermarket bolts with a 12mm hex or socket head. Each:
$ 3.95



LOWER (OUTER) FORK TUBES AND PARTS:

Dust Wiper Seals:

HCP1820 OEM lower fork tube DUST WIPER SEAL, fits either left or right tube on the following models: all XJ550 Maxim, all XJ650 Euro models, and XJ650RJ Seca models. One seal does one tube. Each:
$ 24.95

HCP21555 Aftermarket lower fork tube DUST WIPER SEAL, fits either left or right tube on the following models: all XJ550 Maxim, all XJ650 Euro models, and XJ650RJ Seca models. One seal does one tube. Each:
$ 17.95


HCP1821 OEM lower fork tube DUST WIPER SEAL, fits either left or right tube on the following models: all XJ550 Seca models. One seal does one tube. Each:
$ 19.95

HCP21556 Aftermarket lower fork tube DUST WIPER SEAL, fits either left or right tube on the following models: all XJ550 Seca models. One seal does one tube. Each:
$ 16.95



Oil Seals:

NOTE: when installing oil seals, make sure that the area where the seal will fit into is clean, free of any nicks and burrs, and that the lower tube metal slide bushing is fully seated. Oil seals install with the large opening facing down, into the tube, and on most seals, the small cast lettering and numbering on the seal faces upwards.

Seals are designed to be installed with a seal driver of some type, although a properly sized piece of hard plastic tubing, perhaps with a proper sized metal washer on top of the seal to "spread the load", works as well. Always make sure that oil seals are fully seated and not damaged or installed in a crooked or cocked manner.


HCP1814 OEM lower fork tube OEM OIL SEAL, fits either left or right tube on the following models: XJ550 Maxim, FJ600, all XJ650 Euro models, XJ650 Maxim and Midnight Maxim, XJ650RJ Seca, 1982 XJ650 Turbo, XJ750-P (24L model), and all XJ750 Maxim and Midnight Maxim models. One seal does one tube. Each:
$ 12.95

HCP20643 Aftermarket standard quality lower fork tube BLACK OIL SEALS, fits all of the following models: XJ550 Maxim, FJ600, all XJ650 Euro models, XJ650 Maxim and Midnight Maxim, XJ650RJ Seca, 1982 XJ650 Turbo, XJ750-P (24L model), and all XJ750 Maxim and Midnight Maxim. Comes packaged as a pair of seals, enough to do both forks.
$ 19.95

HCP1716 Aftermarket oem-quality lower fork tube BLACK OIL SEALS, fits all of the following models: XJ550 Maxim, FJ600, all XJ650 Euro models, XJ650 Maxim and Midnight Maxim, XJ650RJ Seca, 1982 XJ650 Turbo, XJ750-P (24L model), and all XJ750 Maxim and Midnight Maxim. Comes packaged as a pair of seals, enough to do both forks.
$ 22.95

HCP20112 Aftermarket premium quality lower fork tube BLACK OIL SEALS, fits all of the following models: XJ550 Maxim, FJ600, all XJ650 Euro models, XJ650 Maxim and Midnight Maxim, XJ650RJ Seca, 1982 XJ650 Turbo, XJ750-P (24L model), and all XJ750 Maxim and Midnight Maxim. NOTE: these seals feature a specially design lip and spring tensions that result in a much lower sliding friction between the seal and the fork tube. Comes packaged as a pair of seals, enough to do both forks.
$ 32.95



HCP1815 OEM lower fork tube OEM OIL SEAL, fits either left or right tube on the following models: XJ550 Seca models. One seal does one tube. Each:
$ 27.50

HCP20642 Aftermarket standard quality lower fork tube BLACK OIL SEALS, fits all of the following models: XJ550 Seca models. Comes packaged as a pair of seals, enough to do both forks.
$ discontinued

HCP1717 Aftermarket premium-quality lower fork tube BLACK OIL SEALS, fits all of the following models: XJ550 Seca models. Comes packaged as a pair of seals, enough to do both forks.
$ 39.95



Oil Seal Retaining Clips:

HCP1827 OEM lower fork tube OIL SEAL RETAINING CLIP, fits either left or right tube on the following models: all XJ550 models, FJ600, all XJ650 Euro models, XJ650 Maxim and Midnight Maxim, XJ650RJ Seca, 1982 XJ650 Turbo, XJ750-P (24L model), and all XJ750 Maxim and Midnight Maxim models. One clip does one tube. Highly recommended that these be replaced when replacing your oil seals! Each:
$ 9.95

HCP20716 Aftermarket lower fork tube OIL SEAL RETAINING CLIP, fits either left or right tube on the following models: all XJ550 models, FJ600, all XJ650 Euro models, XJ650 Maxim and Midnight Maxim, XJ650RJ Seca, 1982 XJ650 Turbo, XJ750-P (24L model), and all XJ750 Maxim and Midnight Maxim models. One clip does one tube. Highly recommended that these be replaced when replacing your oil seals! Each:
$ 6.95



Lower Tube Metal Slider Bushings:

HCP19996 OEM lower fork tube METAL SLIDE BUSHING, fits either left or right lower tube on the following models: all XJ550 Maxim, 1984-85 FJ600, XJ650RJ Seca, 1982 XJ650 Turbo, XJ750P (24L models), XJ750RL (44X Canadian model), and 1983 XJ750 Maxim and Midnight Maxim models. One slider does one tube. Each:
$ 24.95

HCP19996SET2 OEM lower fork tube METAL SLIDE BUSHINGS, set of 2:
$ 47.95


HCP10706 Aftermarket lower fork tube METAL SLIDE BUSHING, fits either left or right lower tube on the following models: all XJ550 Maxim, 1984-85 FJ600, XJ650RJ Seca, 1982 XJ650 Turbo, XJ750P (24L models), XJ750RL (44X Canadian model), and 1983 XJ750 Maxim and Midnight Maxim models. One slider does one tube. Each:
$ 19.95

HCP10706SET2 Aftermarket lower fork tube METAL SLIDE BUSHINGS, set of 2:
$ 37.95



HCP10707C Aftermarket lower fork tube METAL SLIDE BUSHING, fits either left or right lower tube on the following models: all XJ550 Seca and all XJ550 Euro models. One slider does one tube. Each:
$ 29.95

HCP10707CSET2 Aftermarket lower fork tube METAL SLIDE BUSHINGS, set of 2:
$ 57.95



Lower Fork Tube Oil Drain Screw and Gasket:

HCP5187 OEM lower fork tube oil DRAIN SCREW, use one per tube. Natural finish, was originally black on models with black tubes. Fits all XJ-series bikes (except XJ1100 models) and all XS1100 Standard models. Each:
$ 1.95

HCP6708 Aftermarket lower fork tube oil DRAIN SCREW, use one per tube, panhead phillips-drive zinc-plated alloy steel. Fits all XJ-series bikes (except XJ1100 models) and all XS1100 Standard models. Each:
$ 0.95

HCP6709 Aftermarket lower fork tube oil DRAIN SCREW, use one per tube, panhead phillips-drive 18-8 stainless steel, bright finish. Fits all XJ-series bikes (except XJ1100 models) and all XS1100 Standard models. Each:
$ 1.00

HCP6710 Aftermarket lower fork tube oil DRAIN SCREW, use one per tube, panhead phillips-drive 18-8 stainless steel, black-oxide coated finish. Fits all XJ-series bikes (except XJ1100 models) and all XS1100 Standard models. Each:
$ 1.25

HCP6712 Aftermarket lower fork tube oil DRAIN SCREW, use one per tube, socket head cap screw, hex-drive, 18-8 stainless steel, bright finish. Fits all XJ-series bikes (except XJ1100 models) and all XS1100 Standard models. Each:
$ 1.00

HCP6711 Aftermarket lower fork tube oil DRAIN SCREW, use one per tube, socket head cap screw, hex-drive, black-oxide coated finish. Fits all XJ-series bikes (except XJ1100 models) and all XS1100 Standard models. Each:
$ 1.00


HCP7111 OEM lower fork tube oil drain screw GASKET, use one per tube. Fits all XJ-series bikes (except XJ1100 models) and all XS1100 Standard models. Each:
$ 1.95

HCP21320 Aftermarket lower fork tube oil drain screw GASKET, use one per tube. Fits all XJ-series bikes (except XJ1100 models) and all XS1100 Standard models. Each:
$ 1.50

HCP21320SET2 Aftermarket lower fork tube oil drain screw GASKET, use one per tube. Fits all XJ-series bikes (except XJ1100 models) and all XS1100 Standard models. Per pair:
$ 2.95



Lower Fork Tube Damper Rod Retaining Bolt and Gasket:

HCP8233 OEM fork tube damper rod RETAINING SCREW. For all XJ550, 1984-85 FJ600, 1992-98 XJ600 Seca II, XJ650, XJ700, XJ750 (except 1981-83 XJ750 Seca or XJ750 Euro), XJ750RL, XJ900, and XS1100 Standard models. Use 1 per tube. Each:
$ 6.95

HCP12949 Aftermarket fork tube damper rod RETAINING SCREW. For all XJ550, 1984-85 FJ600, 1992-98 XJ600 Seca II, XJ650, XJ700, XJ750 (except 1981-83 XJ750 Seca or XJ750 Euro), XJ750RL, XJ900, and XS1100 Standard models. Use 1 per tube. Each:
$ 4.95

HCP8234 OEM fork tube damper rod retaining screw copper crush washer GASKET. For all XJ550, 1984-85 FJ600, 1992-98 XJ600 Seca II, XJ650, XJ700, XJ750 (except 1981-83 XJ750 Seca or XJ750 Euro), XJ750RL, XJ900, and XS1100 Standard models. Use 1 per tube. Each:
$ 9.50

HCP12950 Aftermarket fork tube damper rod retaining screw copper crush washer GASKET. For all XJ550, 1984-85 FJ600, 1992-98 XJ600 Seca II, XJ650, XJ700, XJ750 (except 1981-83 XJ750 Seca or XJ750 Euro), XJ750RL, XJ900, and XS1100 Standard models. Use 1 per tube. Each:
$ 6.95


w) Lower Fork Tube DAMPER ROD RETAINING TOOL. This long aluminum tool, with proper sized nuts on each end, is used to retain the top of the fork damper rod (in the bottom of the chrome tube) when removing or installing the damper rod retaining screw. One end has a 19mm hex and the other end has a 22mm hex, so it will fit all styles of XJ-series bikes except XJ600 Seca II, 1981-83 XJ750 Seca, XJ1100, and all XS1100 Special and Midnight Special models. This tool will make the disassembly of your upper tube from the lower tube much easier! NOTE: this tool is available for short term rental, please see the “rental” section within the THE TOOLBOX section of our catalog at:

http://xjbikes.com/forums/index.php?threads/xj-parts-catalog-section-p-the-toolbox.44630

and review the availability and procedures in the TOOL RENTAL section.

HCP4402 Aftermarket DAMPER ROD RETAINING TOOL.
$ 29.95



Lower Fork Tube Speedometer Cable Hardware:

HCP2182 OEM lower fork tube speedometer cable bracket mounting BOLT, 6-point hex head alloy steel fastener with a bright finish, on the left fork tube only, use 1 on all XJ550 Maxim, XJ650 Maxim, XJ750 Maxim, 1981 XJ750 Seca, XJ1100, and XS1100 Standard and Special models. Bright plating. Use with the HCP315, HCP916, or HCP319 lock washer below. Each:
$ 2.95

HCP22180 Aftermarket lower fork tube speedometer cable bracket mounting BOLT, 6-point hex head alloy steel fastener with a dark finish, on the left fork tube only, use 1 on all XJ550 Maxim, XJ650 Maxim, XJ750 Maxim, 1981 XJ750 Seca, XJ1100, and XS1100 Standard and Special models. Bright plating. Use with the HCP315, HCP916, or HCP319 lock washer below. Each:
$ 1.25

HCP22182 Aftermarket lower fork tube speedometer cable bracket mounting BOLT, 6-point hex head 18/8 stainless steel fastener with a bright finish, on the left fork tube only, use 1 on all XJ550 Maxim, XJ650 Maxim, XJ750 Maxim, 1981 XJ750 Seca, XJ1100, and XS1100 Standard and Special models. Bright plating. Use with the HCP315, HCP916, or HCP319 lock washer below. Each:
$ 1.75

HCP22183 Aftermarket lower fork tube speedometer cable bracket mounting BOLT, 6-point hex head 316 stainless steel fastener with a bright finish, on the left fork tube only, use 1 on all XJ550 Maxim, XJ650 Maxim, XJ750 Maxim, 1981 XJ750 Seca, XJ1100, and XS1100 Standard and Special models. Bright plating. Use with the HCP315, HCP916, or HCP319 lock washer below. Each:
$ 1.95

HCP22181 Aftermarket lower fork tube speedometer cable bracket mounting BOLT, 6-point hex head alloy steel fastener has a serrated flange (which eliminates the need for using a lockwasher) and features a dark finish, on the left fork tube only, use 1 on all XJ550 Maxim, XJ650 Maxim, XJ750 Maxim, 1981 XJ750 Seca, XJ1100, and XS1100 Standard and Special models. Bright plating. Use with the HCP315, HCP916, or HCP319 lock washer below. Each:
$ 1.95



HCP315 OEM lower fork tube speedometer cable bracket mounting bolt LOCK WASHER, bright finish, use 1 per bike on the following models: all XJ550 Maxim models, all XJ650 Maxim and Midnight Maxim models, all XJ750 Maxim models, 1981 XJ750 Seca models, XJ1100, and all XS1100 models.
$ 1.50

HCP1902 OEM lower fork tube speedometer cable bracket mounting bolt LOCK WASHER, black finish, use 1 per bike on the following models: XJ650 Midnight Maxim, 1982-83 XJ750 Seca, XJ750 Euro, XJ750 Midnight Maxim, and XS1100 Midnight Special models.
$ 1.95

HCP916 Aftermarket zinc-plated alloy steel with a natural finish, lower fork tube speedometer cable bracket mounting bolt LOCK WASHER, use 1 per bike on the following models: all XJ550 Maxim models, all XJ650 Maxim and Midnight Maxim models, all XJ750 Maxim models, 1981 XJ750 Seca models, XJ1100, and all XS1100 models:
$ 1.00

HCP319 Aftermarket 18-8 stainless steel lower fork tube speedometer cable bracket mounting bolt LOCK WASHER, use 1 per bike on the following models: all XJ550 Maxim models, all XJ650 Maxim and Midnight Maxim models, all XJ750 Maxim models, 1981 XJ750 Seca models, XJ1100, and all XS1100 models:
$ 1.00

HCP321 Aftermarket black oxide-coated alloy steel lower fork tube speedometer cable bracket mounting bolt LOCK WASHER, use 1 per bike on the following models: all XJ550 Maxim models, all XJ650 Maxim and Midnight Maxim models, all XJ750 Maxim models, 1981 XJ750 Seca models, XJ1100, and all XS1100 models:
$ 1.50



Lower Fork Tube Axle Retaining Hardware:

HCP4827 OEM front axle shaft-to-lower tube RETAINING BOLT, use 1 per bike on the right side lower fork tube. For all XJ550 Maxim, XJ650 Maxim, and 1983 XJ750 Maxim models.
$ 5.95

HCP4828 OEM front axle shaft-to-lower tube RETAINING BOLT, use 1 per tube (2 per bike) on both the left and right side lower fork tube. For all XJ550 Seca, 1984-85 FJ600, all XJ650 Euro models, XJ650RJ Seca and XJ650 Turbo models, XJ750RL, XJ750P (37H model), and XJ900RK, RL, N/FN, and F models. Each:
$ 2.95



HCP2537 OEM front axle shaft-to-lower tube retaining bolt FLAT WASHER, alloy steel, bright finish, for all 1981 XJ550 Seca models, 1984-85 FJ600, all XJ650 Euro models, XJ650RJ Seca and XJ650 Turbo models, XJ750RL, XJ750P (37H model), XJ700-X and XJ750-X models, XJ900RK, RL, N/FN, and F models. Use 2 per retaining bolt (4 per bike) on both the left and right side lower fork tubes. NOTE: XJ700-X and XJ750-X models only use 1 of the washers per bike). Each:
$ 1.95

HCP3945 OEM front axle shaft-to-lower tube retaining bolt FLAT WASHER, alloy steel, black finish, for all 1982-83 XJ550 Seca models. Use 2 per tube (4 per bike) on both the left and right side lower fork tube. Each:
$ 1.95

HCP26192 Aftermarket front axle shaft-to-lower tube retaining bolt FLAT WASHER, alloy steel, bright finish, for all XJ550 Seca models, 1984-85 FJ600, all XJ650 Euro models, XJ650RJ Seca and XJ650 Turbo models, XJ750RL, XJ750P (37H model), XJ700-X and XJ750-X models, XJ900RK, RL, N/FN, and F models. Use 2 per retaining bolt (4 per bike) on both the left and right side lower fork tubes. NOTE: XJ700-X and XJ750-X models only use 1 of the washers per bike). Each:
$ 0.95

HCP26193 Aftermarket front axle shaft-to-lower tube retaining bolt FLAT WASHER, 18/8 stainless steel, bright finish, for all XJ550 Seca models, 1984-85 FJ600, all XJ650 Euro models, XJ650RJ Seca and XJ650 Turbo models, XJ750RL, XJ750P (37H model), XJ700-X and XJ750-X models, XJ900RK, RL, N/FN, and F models. Use 2 per retaining bolt (4 per bike) on both the left and right side lower fork tubes. NOTE: XJ700-X and XJ750-X models only use 1 of the washers per bike). Each:
$ 1.25

HCP17110 Aftermarket front axle shaft-to-lower tube retaining bolt FLAT WASHER, 316 stainless steel, dull finish, for all XJ550 Seca models, 1984-85 FJ600, all XJ650 Euro models, XJ650RJ Seca and XJ650 Turbo models, XJ750RL, XJ750P (37H model), XJ700-X and XJ750-X models, XJ900RK, RL, N/FN, and F models. Use 2 per retaining bolt (4 per bike) on both the left and right side lower fork tubes. NOTE: XJ700-X and XJ750-X models only use 1 of the washers per bike). Each:
$ 1.95

HCP26189 Aftermarket front axle shaft-to-lower tube retaining bolt FLAT WASHER, alloy steel, black finish, for all XJ550 Seca models, 1984-85 FJ600, all XJ650 Euro models, XJ650RJ Seca and XJ650 Turbo models, XJ750RL, XJ750P (37H model), XJ700-X and XJ750-X models, XJ900RK, RL, N/FN, and F models. Use 2 per retaining bolt (4 per bike) on both the left and right side lower fork tubes. NOTE: XJ700-X and XJ750-X models only use 1 of the washers per bike). Each:
$ 2.95



HCP2185 OEM front axle shaft-to-lower tube retaining bolt LOCK WASHER, use 1 per bike on the following models: all XJ550 Maxim models, 1984-85 FJ600, all XJ650 Maxim models, all XJ700 models, all 1982-83 XJ750 Maxim models, XJ750-X, and XJ1100 models. Use 2 per bike on the following models: all 1981 XJ550 Seca, all XJ650 Euro models, XJ650RJ Seca and XJ650 Turbo models, XJ750-D, XJ750P (37H model), and XJ900RK, RL, and F models. Each:
$ 1.95

HCP16209 Aftermarket front axle shaft-to-lower tube retaining bolt LOCK WASHER, zinc-plated alloy steel, use 1 per bike on the following models: all XJ550 Maxim models, 1984-85 FJ600, all XJ650 Maxim models, all XJ700 models, all 1982-83 XJ750 Maxim models, XJ750-X, and XJ1100 models. Use 2 per bike on the following models: all 1981 XJ550 Seca, all XJ650 Euro models, XJ650RJ Seca and XJ650 Turbo models, XJ750-D, XJ750P (37H model), and XJ900RK, RL, and F models. Each:
$ 0.95

HCP16100 Aftermarket front axle shaft-to-lower tube retaining bolt LOCK WASHER, 18-8 stainless-steel with a bright finish, use 1 per bike on the following models: all XJ550 Maxim models, 1984-85 FJ600, all XJ650 Maxim models, all XJ700 models, all 1982-83 XJ750 Maxim models, XJ750-X, and XJ1100 models. Use 2 per bike on the following models: all 1981 XJ550 Seca, all XJ650 Euro models, XJ650RJ Seca and XJ650 Turbo models, XJ750-D, XJ750P (37H model), and XJ900RK, RL, and F models. Each:
$ 0.95


HCP2391 OEM front axle shaft-to-lower tube retaining bolt LOCK WASHER, use 2 per bike on the following models: all 1982-83 XJ550 Seca, all XJ650 Turbo models. Use 1 per bike on all XJ650 Midnight Maxim and XJ750 Midnight Maxim models. Each:
$ 1.75

HCP16102 Aftermarket front axle shaft-to-lower tube retaining bolt LOCK WASHER, black-oxide coated finish, use 2 per bike on the following models: all 1982-83 XJ550 Seca, all XJ650 Turbo models. Use 1 per bike on all XJ650 Midnight Maxim and XJ750 Midnight Maxim models. Each:
$ 0.95


HCP3494 OEM front axle shaft-to-lower tube retaining bolt NUT, use 1 per bike on the following models: all XJ550 Maxim models, all XJ650 (except Midnight Maxim) models, all XJ700 non-X models, all 1982-83 XJ750 Maxim, XJ750-D, and XJ1100 models. Use 2 per bike on the following models: all XJ550 Seca, 1984-85 FJ600, all XJ650 Euro models, XJ750RL, all XJ900RK, RL, N/FN, and F models, and 1979 XS1100 Special models. Each:
$ 3.95

HCP24037 Aftermarket front axle shaft-to-lower tube retaining bolt NUT, made from 18/8 stainless steel, use 1 per bike on the following models: all XJ550 Maxim models, all XJ650 (except Midnight Maxim) models, all XJ700 non-X models, all 1982-83 XJ750 Maxim, XJ750-D, and XJ1100 models. Use 2 per bike on the following models: all XJ550 Seca, 1984-85 FJ600, all XJ650 Euro models, XJ750RL, all XJ900RK, RL, N/FN, and F models, and 1979 XS1100 Special models. Each:
$ 2.95



Lower Tube ID Decal:

HCP8500 Aftermarket suspension ID DECAL, small black rectangular decal with silver lettering "KYB", used as follows:

- mounts directly above the lower fork tube drain screw and faces the rear of the bike. Use 1 on the left side fork tube on XJ550 Maxim, all XJ650 (except Turbo) models, all XJ700 and XJ750-X models, and 1 on the right side fork tube on XJ550 Seca models.

- mounts directly below the lower vertical adjuster stop peg on the rear shock absorbers. Use 1 per shock on all XJ550 models and all XJ650 (except Turbo) models original rear shocks.

Each:
$ 8.95



FORK SYSTEM SERVICE TOOLS:

Assembly and Dis-assembly Tools:

NOTE: many of these tools are available for short term rental, please see the “rental” section within the THE TOOLBOX section of our catalog at:

http://xjbikes.com/forums/index.php?threads/xj-parts-catalog-section-p-the-toolbox.44630

and review the availability and procedures in the TOOL RENTAL section.


w) Lower Fork Tube DAMPER ROD RETAINING TOOL. This long aluminum tool, with proper sized nuts on each end, is used to retain the top of the fork damper rod (in the bottom of the chrome tube) when removing or installing the damper rod retaining screw. One end has a 19mm hex and the other end has a 22mm hex, so it will fit all styles of XJ-series bikes except XJ600 Seca II, 1981-83 XJ750 Seca, XJ1100, and all XS1100 Special and Midnight Special models. This tool will make the disassembly of your upper tube from the lower tube much easier!

HCP4402 Aftermarket DAMPER ROD RETAINING TOOL.
$ 29.95


HCP15939 Aftermarket lower fork tube OIL SEAL DRIVER. split “clamshell” heavy duty design features adjustable inserts that allow it to be used properly and safely install the lower tube oil seals and (where applicable) lower tube dust seals on all 35-43mm fork tubes (which covers the entire XJ- and XS-series line of bikes).
$ 39.95



Super-Penetrant Fluids and Lubricants:

Sometimes, the toughest part of working on a vehicle is battling the effects of time: seized fasteners, caused by rust, corrosion, and other factors, turns what should be a 5-minute effort into a 50-minute (or more) chore, complete with rounded-off, ruined, or snapped fasteners, e-z outs, heli-coil inserts, and more.........and that's just not right.

While the proper use of our various Anti-Seize products will prevent these nightmares from occurring in the future, you're stuck in the here-and-now, and the best way to handle these obstacles is to have the proper tools at the stand-by; and in the case of fastener seizure, the proper "tool" is a can or two of our SUPER PENETRATING LUBRICANTS at the ready; a couple of squirts, a little bit of time-----perhaps some heat for those really nasty situations----and you're on your way again, hopefully not too much worse for the experience.....

Great for use on all fasteners, fork tube cap bolts, intake and exhaust manifolds bolts, studs, and nuts, lock cylinder tumblers, or anywhere an un-cooperative fastener can be found. Can even be used to help un-seize frozen engines!

Be aware that these products are not your typical, garden-variety, run-of-the-mill "retail" type products; these are designed an used as industrial- and military-strength products, meaning they have special formulations that include a dollop more of the "good stuff" within them to solve the toughest seizure problems imaginable (the "good stuff" ingredients cost more, and it is those compounds that are left out of or reduced in concentration in "retail" level consumer products).

NOTE: the following product(s) can only be shipped via ground transport (which thus eliminates the Priority Mail level of service for this item) and cannot (and will not----don't even ask!) be shipped outside of the continental USA. Therefore it may have to be shipped in a separate package from the remainder of your order, and will thus incur additional shipping charges.

HCP10331 Aftermarket standard-duty PENETRATING LUBRICANT, in a generous 16-ounce aerosol can. Oil-based lubricant penetrates down into spaces of one-millionth of an inch to handle the most reluctant seizures. Actually dissolves the rust and corrosion that causes the seizure; lubricates and displaces moisture to prevent rust re-formation. This product is what we use and recommend for freeing stuck fork tube cap bolts and other such challenging fasteners.
$ 24.95

HCP11974 Aftermarket super-duty PENETRATING LUBRICANT, in a generous 13-ounce aerosol can. Same as our standard-duty formula above, but also includes graphite to not only enhance and speed up the penetrant action, but also gets down into the pores of the metal for the greatest possible lubrication possible. The cat's-meow of penetrating fluids, can even be used to un-seize frozen engines or as an engine assembly lube! This fluid is also a great choice for use as a drive cable lubricant.
$ 26.95

HCP10333 Aftermarket extreme-duty PENETRATING LUBRICANT, in a generous 16-ounce aerosol can. Same as our standard-duty formula above, but also includes liquid silicone to enhance and speed up the penetrant action. This product is also an exceptional choice for use as a control-cable lubricant.
$ 27.95



Assembly Fluids and Lubricants:

NOTE: the following product(s) can only be shipped via ground transport (which thus eliminates the Priority Mail level of service for this item) and cannot (and will not----don't even ask!) be shipped outside of the continental USA. Therefore it may have to be shipped in a separate package from the remainder of your order, and will thus incur additional shipping charges.

HCP20860 Aftermarket industrial-strength ASSEMBLY LUBE, in a standard 12-ounce aerosol can. Heavy-duty formula includes graphite to not only enhance and speed up the penetrant action, but also gets down into the pores of the metal for the greatest possible lubrication possible. Won't wash away, protect against rust and corrosion, stable from 0-degrees up to 250-F. This fluid is also a great choice for use as a drive cable lubricant.
$ 21.95

HCP20862 Aftermarket super-duty ASSEMBLY LUBE, in a generous 10-ounce aerosol can. The cat's-meow of lubricants, infused with pure moly disulfide, it goes on wet and then dries in 1-2 hours to a super-slick, high-pressure, hi-temp, bearing-like finish which provides the ultimate level of protection. Prevents rust and corrosion, won't wash off, throw off, and won't attract dust or dirt. Surfaces must be clean and dry of previous oils, etc. before application. Can even be used as an engine, tranny, and drivetrain assembly lube!
$ 24.95

HCP20863 Aftermarket super-duty GRAPHITE LUBE, in a generous 10-ounce aerosol can. The 800-pound gorilla of lubricants, it's infused with pure graphite, goes on wet, and then dries in 10 minutes to a super-slick, high-pressure, bearing-like finish which provides the ultimate level of protection. Prevents rust, won't wash off, throw off, and won't attract dust or dirt. Surfaces must be clean and dry of previous oils, etc. before application. Can be used as an engine assembly lube, bearing or bushing pre-lube, great for lock cylinders, and all metallic sliding surfaces. Use where dusty or dirty conditions render oil-based lubricants ineffective or undesirable.
$ 21.95



Fork Tube Cleaning and Polishing:

HCP9208 Fork Tube DEEP REACH CLEANING BRUSH. This 30" long handled brush features vinyl-covered wires that can reach deep inside the forks tubes to clean away grit and oil sludge residue that cannot otherwise be reached or disturbed. Use with your favorite cleaning solvents to get the insides of the fork tubes free of contaminants.
$ discontinued


ft4) These stainless-steel, bristle-wire DE-BURRING BRUSHES will work wonders on the upper cap bolt area on both the threaded and the non-threaded style of fork tubes. Tubes that use threaded cap bolt (all XJ650 Turbo, all XJ700 models, XJ750-X models, XJ750 Maxim and Midnight Maxim, XJ900RK, and XJ1100 models) should use the HCP10223 butterfly brush; non-threaded tubes can use either the HCP10222 spiral brush or the HCP10223 butterfly brush. Both style brushes have stems that are designed to be used in a standard power drill, and should be used at 850 rpm's or less. These brushes will make quick and meaningful work of the cleaning and polishing of this critical area on your upper fork tubes.

HCP10222 Aftermarket stainless-steel double-density spiral DE-BURRING BRUSH, for use on fork tubes without a threaded cap bolt.
$ 8.25

HCP10223 Aftermarket stainless-steel high-density "butterfly-wings" DE-BURRING BRUSH, for use on fork tubes with or without threaded cap bolts.
$ 8.25



Fork Tube Oil Level Gauges:

HCP1728 Fork tube oil fluid level measurement GAUGE AND SYRINGE. This handy tool makes the measurement of the fork oil level easy and accurate. NOTE: the proper amount of fork oil is determined via the measurement of the fork oil LEVEL (distance below the very top of the inner tube) rather than a volume AMOUNT of oil specification. Too little oil will make the ride mushy, while too much oil makes the ride harsh (and can blow out the oil seals!)
$ 29.95



ffl4) Aftermarket fork oil measurement GRADUATED CYLINDERS. The best way to measure the precise amount of fork oil fluid is via the use of these lab-quality measurement cylinders. Available in either transparent (clear) or translucent (cloudy) durable plastic construction, they all have easy-to-read scale numerals (milliliters) and feature a "non-wetting" inner surface coating that prevents the concave "meniscus" from forming at the top of the fluid, thus insuring a much more accurate level reading. Large bases insure stability while large spouts make "the pour" easy and prevent messy drips. Very useful device to have for front fork oil changes.

HCP10741 Aftermarket fork oil GRADUATED CYLINDER, 250ml capacity, translucent (cloudy).
$ 11.95

HCP10744 Aftermarket fork oil GRADUATED CYLINDER, 250ml capacity, transparent (clear).
$ 24.95

HCP10742 Aftermarket fork oil GRADUATED CYLINDER, 500ml capacity, translucent (cloudy).
$ 12.95

HCP10745 Aftermarket fork oil GRADUATED CYLINDER, 500ml capacity, transparent (clear).
$ 33.95

HCP10743 Aftermarket fork oil GRADUATED CYLINDER, super-sized 1000ml capacity, translucent (cloudy), with convenient side handle to insure steady pouring.
$ 48.95

 
Last edited: Dec 4, 2018
  • chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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    1984-85 FJ600 MODELS FORK TUBE PARTS:

    NOTE: items marked below in red are the parts typically needed when doing a basic fork system rebuild.

    A good visual review of the procedures needed for rebuilding these forks can be seen at:

    http://xjbikes.com/forums/index.php?threads/8355

    And these incredible 3-D renderings of the inner workings of a forking system gives a great visualization of the internal components (it is based on the 1982-83 XJ650 Maxim forks):



    and

    http://xjbikes.com/forums/index.php?threads/29616


    FORK TUBE REBUILD PARTS KITS:

    We now offer both a BASIC FORK REBUILD KIT and PERFORMANCE FOR TUBE REBUILD KITS so that you can get all the typically-needed rebuild parts under one simple part number. Each kit is specifically assembled and correct for your particular model bike.

    Basic fork rebuild kit contains at least the following items:
    - cap bolt o-rings.
    - standard quality lower fork tube oil seals.
    - oil seal retaining clips.
    - oil drain screws and gaskets.
    - damper rod bolts and crush washers.
    - damper rod head piston rings.
    - air system o-rings and air valve cores (in the 1985 model kits).
    - NOTE: 1984 owners may wish to purchase the HCP9238 cap bolt removal tool, as it is not included in the HCP20710 kit!

    HCP20710 Aftermarket fork tubes BASIC FORK REBUILD KIT. For all 1984 FJ600 models. One kit does both front tubes.
    $ 84.95

    HCP20605 Aftermarket fork tubes BASIC FORK REBUILD KIT. For all 1985 FJ600 models. One kit does both front tubes.
    $ 89.95


    Performance fork rebuild kit contain all of the basic rebuild kit components, along with:
    - performance fork springs.
    - upgraded, high-performance lower fork tube oil seals.
    - lower fork tube dust boots.
    - air valve core stem tool (in the 1985 model kit).
    - NOTE: 1984 owners may wish to purchase the HCP9238 cap bolt removal tool (listed further below), as it is not included in the HCP20711 kit.

    HCP20711 Aftermarket fork tubes PERFORMANCE FORK REBUILD KIT. For all 1984 FJ600 models. One kit does both front tubes.
    $ 244.95

    HCP20606 Aftermarket fork tubes PERFORMANCE FORK REBUILD KIT. For all 1985 FJ600 models. One kit does both front tubes.
    $ 249.95


    Of course, all of the component pieces can be ordered as individual pieces from the selections listed below, as well as non-typical wear items (inner tubes, damper rod piston rings, taper spindles, cap bolts, etc.), as well as the fork oil and specialty tools needed to properly restore or enhance your front suspension performance.



    UPPER (INNER) FORK TUBES AND PARTS:

    Chrome Inner Fork Tubes:

    HCP20354 Aftermarket chrome INNER FORK TUBE, fits left or right side, for all 1984 (non air-assisted forks) FJ600 Maxim models, each:
    $ 299.95

    HCP203542SET2 Aftermarket chrome INNER FORK TUBES, set of 2:
    $ 489.95


    HCP19810 Aftermarket chrome INNER FORK TUBE, fits left or right side, for all 1985 (air-assisted forks) FJ600 Maxim models, each:
    $ 299.95

    HCP198102SET2 Aftermarket chrome INNER FORK TUBES, set of 2:
    $ 489.95



    Inner Tube Top Cover/Cap:

    HCP8289 OEM inner fork tube black rubber top CAP, fits either the left or right side tube of the following models: 1984 FJ600, 1982-83 XJ650 Turbo, XJ750RL, XJ750-D, XJ750-P (24L model), and XJ900RK, RL, N/FN, and F Seca models. NOTE: you can substitute the HCP8287 top cap in place of this one for a upgraded appearance! Each:
    $ 17.95

    HCP22880 Aftermarket inner fork tube black rubber top CAP, fits either the left or right side tube of the following models: 1984 FJ600, 1982-83 XJ650 Turbo, XJ750RL, XJ750-D, XJ750-P (24L model), and XJ900RK, RL, N/FN, and F Seca models. NOTE: you can substitute the HCP8287 top cap in place of this one for a upgraded appearance! Each:
    $ 14.95



    Inner Fork Tube Cap Bolts and Related Hardware:

    HCP8292 OEM inner fork tube CAP BOLT, fits either side. Used on all 1984 FJ600, XJ700 non-X, XJ750RL, and XJ900RK, RL, and N/FN Seca models. NOTE: these cap bolts require a special inverse-hex tool HCP9238 to properly remove and install. Each:
    $ 49.95

    HCP9238 Aftermarket fork upper cap bolt REVERSE HEX SOCKET TOOL. This tool allows the easy removal and installation of the "inverted/reversed" hex-drive cap bolt used on the top of the inner fork tubes on all 1984 FJ600, XJ650 Turbo, XJ700 non-X, XJ750-D, XJ750P (37H) model, and all XJ900RK, RL, N/FN, and F models..
    $ 12.95


    HCP8286 OEM inner fork tube cap bolt O-RING, fits either side. Used on all 1984-85 FJ600, XJ700, XJ750-X, XJ750RL, and XJ900RK, RL, N/FN, and F Seca models. Each:
    $ 7.95

    HCP20708 Aftermarket inner fork tube cap bolt O-RING, fits either side. Used on all 1984-85 FJ600, XJ700, XJ750-X, XJ750RL, and XJ900RK, RL, N/FN, and F Seca models. Each:
    $ 4.95



    Inner Tube Fork Springs:

    HCP9437 Aftermarket front suspension PROGRESSIVE-WOUND COIL SPRINGS, one pair does both forks. For all 1984-85 FJ600, all XJ700, and XJ750-X models. No spacers are needed on FJ600 models when using these springs. NOTE: springs should be installed with the tighter (more-closely spaced together) coils towards the top of the fork tube.
    $ 119.95



    Inner Fork Tube Spring Spacers, Rebound Springs, Damper Rods, and Spring Seats:

    HCP8280 OEM inner fork tube SPRING SEAT, fits either side. Used on all 1985 FJ600 models, XJ700, XJ750-X, and XJ900 F models. Each:
    $ 29.95

    HCP20353 OEM inner fork tube SPRING SPACER TUBE, fits either side. Used on all 1985 FJ600 Maxim models. Each:
    $ 13.95


    HCP13657 Aftermarket inner fork tube damper rod PISTON RING, fits either side. Used on all 1984-85 FJ600, all XJ700, XJ750-X, XJ750RL Canadian (44X model), and XJ900 models. Use 1 per fork tube. Each:
    $ 9.95



    Inner Fork Tube Taper Spindle:

    HCP3085 OEM upper (inner) fork tube TAPER SPINDLE, fits either side. Fits all XJ550 models, 1984 FJ600, all XJ650 models, all XJ700 and XJ750-X models, all XJ750 Maxim and Midnight Maxim models, XJ900 N/FN and F models, and all XS1100 Standard models. Each:
    $ 16.95



    INNER FORK TUBE AIR SYSTEM PARTS:

    Air Inflation Valves and O-Rings:

    HCP20350 OEM inner fork tube air joint AIR VALVE, comes complete the internal stem core, its o-ring, and black cap. Use 1 per tube. Fits the following models: 1985 FJ600 models. Each:
    $ 49.95


    HCP2322 OEM inner fork tube air joint air valve and air hose-to-joint O-RING, fits the following models: 1985 FJ600 models (use 1 per tube), 1982-83 XJ650 Maxim (use 1 per tube), XJ650 Turbo models (use 3 per bike), XJ750-P (24L and 37H models, use 2 per bike), XJ750-D (use 3 per bike), 1982 XJ750 Maxim (use 3 per bike), 1983 XJ750 Maxim and Midnight Maxim models (use 3 per bike), and XJ900RK and RL models (use 3 per bike). Each:
    $ 4.95

    HCP14020 Aftermarket inner fork tube air joint air valve and air hose-to-joint O-RING, fits the following models: 1985 FJ600 models (use 1 per tube), 1982-83 XJ650 Maxim (use 1 per tube), XJ650 Turbo models (use 3 per bike), XJ750-P (24L and 37H models, use 2 per bike), XJ750-D (use 3 per bike), 1982 XJ750 Maxim (use 3 per bike), 1983 XJ750 Maxim and Midnight Maxim models (use 3 per bike), and XJ900RK and RL models (use 3 per bike). Each:
    $ 2.95



    HCP9194 Aftermarket fork tube AIR VALVE STEM CORE, internal brass valve core with o-ring exactly replaces leaking and damaged originals on all 1985 FJ600 models, 1982-83 XJ650 Maxim and Turbo models, XJ700-X models, all XJ750 models, the XJ900RK model, XJ1100, and all XS1100 Special and Midnight Special models. If your stem is leaking air, this is the inexpensive way to fix it. Each:
    $ 1.25

    HCP9194SET2 Aftermarket fork tube AIR VALVE STEM CORES, set of 2:
    $ 1.95



    HCP9196 Aftermarket AIR VALVE STEM TOOL, handy 4-in-1 tool allows you to properly remove and insert the stem core, and also clean/chase/re-thread the internal and external stem threads.
    $ 4.95



    HCP20351 OEM fork tube air fill valve CAP. Used on all 1985 FJ600 models, one on each valve. Each:
    $ 7.95



    INNER FORK TUBE RETAINING HARDWARE:

    Crown Bracket Inner Fork Tube Retaining Hardware:

    HCP4960 OEM under-bracket fork tube CINCH BOLT, alloy steel, socket head cap screw with a bright finish. Use 2 per side on all 1981-83 XJ550 Seca models, and 1 per side on all 1984-85 FJ600 models. This bolt also secures the horn bracket to the under-bracket. Each:
    $ discontinued

    HCP21945 Aftermarket under-bracket fork tube CINCH BOLT, alloy steel, socket head cap screw with a bright finish. Unlike the original fastener, this bolt does not have a captive lock-washer, and a separate lock-washer should be used. Use 2 per side on all 1981-83 XJ550 Seca models, and 1 per side on all 1984-85 FJ600 models. This bolt also secures the horn bracket to the under-bracket. Each:
    $ 4.95

    HCP21946 Aftermarket under-bracket fork tube cinch bolt LOCK WASHER, zinc-plated alloy steel with a bright finish. Use 1 per bolt on all 1981-83 XJ550 Seca and 1984-85 FJ600 models. Each:
    $ 1.25

    HCP21947 Aftermarket under-bracket fork tube cinch bolt LOCK WASHER, 18/8 stainless steel with a bright finish. Use 1 per bolt on all 1981-83 XJ550 Seca and 1984-85 FJ600 models. Each:
    $ 1.25

    HCP21948 Aftermarket under-bracket fork tube cinch bolt LOCK WASHER, black oxide-coated alloy steel. Use 1 per bolt on all 1981-83 XJ550 Seca and 1984-85 FJ600 models. Each:
    $ 1.25



    HCP3945 OEM crown bracket fork tube FLAT WASHER, alloy steel, black finish, for use on all of the following models: 1984-85 FJ600 (use 2 per side), all 1981-83 XJ650 Maxim and Midnight Maxim models (use 2 for the rear lateral cinch bolt), 1982 XJ650RJ Seca (use 2 per side), 1983 XJ750 Maxim and Midnight Maxim models (use 2 per side), 1980-81 XS1100 Standard models (use 2 per bolt, total of 6 per bike), and all XS1100 Special and Midnight Special models (use 2 per bolt). Each:
    $ 1.95

    HCP26192 Aftermarket crown bracket fork tube FLAT WASHER, alloy steel, bright finish, for use on all of the following models: 1984-85 FJ600 (use 2 per side), all 1981-83 XJ650 Maxim and Midnight Maxim models (use 2 for the rear lateral cinch bolt), 1982 XJ650RJ Seca (use 2 per side), 1983 XJ750 Maxim and Midnight Maxim models (use 2 per side), 1980-81 XS1100 Standard models (use 2 per bolt, total of 6 per bike), and all XS1100 Special and Midnight Special models (use 2 per bolt). Each:
    $ 0.95

    HCP26193 Aftermarket crown bracket fork tube FLAT WASHER, 18/8 stainless steel, bright finish, for use on all of the following models: 1984-85 FJ600 (use 2 per side), all 1981-83 XJ650 Maxim and Midnight Maxim models (use 2 for the rear lateral cinch bolt), 1982 XJ650RJ Seca (use 2 per side), 1983 XJ750 Maxim and Midnight Maxim models (use 2 per side), 1980-81 XS1100 Standard models (use 2 per bolt, total of 6 per bike), and all XS1100 Special and Midnight Special models (use 2 per bolt). Each:
    $ 1.25

    HCP17110 Aftermarket crown bracket fork tube FLAT WASHER, 316 stainless steel, dull finish, for use on all of the following models: 1984-85 FJ600 (use 2 per side), all 1981-83 XJ650 Maxim and Midnight Maxim models (use 2 for the rear lateral cinch bolt), 1982 XJ650RJ Seca (use 2 per side), 1983 XJ750 Maxim and Midnight Maxim models (use 2 per side), 1980-81 XS1100 Standard models (use 2 per bolt, total of 6 per bike), and all XS1100 Special and Midnight Special models (use 2 per bolt). Each:
    $ 1.95

    HCP26189 Aftermarket crown bracket fork tube FLAT WASHER, alloy steel, black finish, for use on all of the following models: 1984-85 FJ600 (use 2 per side), all 1981-83 XJ650 Maxim and Midnight Maxim models (use 2 for the rear lateral cinch bolt), 1982 XJ650RJ Seca (use 2 per side), 1983 XJ750 Maxim and Midnight Maxim models (use 2 per side), 1980-81 XS1100 Standard models (use 2 per bolt, total of 6 per bike), and all XS1100 Special and Midnight Special models (use 2 per bolt). Each:
    $ 2.95



    HCP2391 OEM crown bracket fork tube LOCK WASHER, for use on all 1984-85 FJ600 models. Use 1 per side. Each:
    $ 1.75

    HCP16102 Aftermarket crown bracket fork tube LOCK WASHER, black-oxide coated finish, for use on all 1984-85 FJ600 models. Use 1 per side. Each:
    $ 0.95



    LOWER (OUTER) FORK TUBES AND PARTS:

    Dust Wiper Seals:

    HCP1823 OEM lower fork tube DUST WIPER SEAL, fits either left or right tube on the following models: 1984-85 FJ600, all XJ650 Maxim and Midnight Maxim, 1982 XJ650 Turbo, XJ750-P (24L model), and XJ750 Maxim and Midnight Maxim models. One seal does one tube. Each:
    $ 22.95

    HCP21557 Aftermarket lower fork tube DUST WIPER SEAL, fits either left or right tube on the following models: 1984-85 FJ600, all XJ650 Maxim and Midnight Maxim, 1982 XJ650 Turbo, XJ750-P (24L model), and XJ750 Maxim and Midnight Maxim models. One seal does one tube. Each:
    $ 17.95



    Oil Seals:

    NOTE: when installing oil seals, make sure that the area where the seal will fit into is clean, free of any nicks and burrs, and that the lower tube metal slide bushing is fully seated. Oil seals install with the large opening facing down, into the tube, and on most seals, the small cast lettering and numbering on the seal faces upwards.

    Seals are designed to be installed with a seal driver of some type, although a properly sized piece of hard plastic tubing, perhaps with a proper sized metal washer on top of the seal to "spread the load", works as well. Always make sure that oil seals are fully seated and not damaged or installed in a crooked or cocked manner.

    HCP1814 OEM lower fork tube OEM OIL SEAL, fits either left or right tube on the following models: XJ550 Maxim, FJ600, all XJ650 Euro models, XJ650 Maxim and Midnight Maxim, XJ650RJ Seca, 1982 XJ650 Turbo, XJ750-P (24L model), and all XJ750 Maxim and Midnight Maxim models. One seal does one tube. Each:
    $ 12.95

    HCP20643 Aftermarket standard quality lower fork tube BLACK OIL SEALS, fits all of the following models: XJ550 Maxim, FJ600, all XJ650 Euro models, XJ650 Maxim and Midnight Maxim, XJ650RJ Seca, 1982 XJ650 Turbo, XJ750-P (24L model), and all XJ750 Maxim and Midnight Maxim. Comes packaged as a pair of seals, enough to do both forks.
    $ 19.95

    HCP1716 Aftermarket oem-quality lower fork tube BLACK OIL SEALS, fits all of the following models: XJ550 Maxim, FJ600, all XJ650 Euro models, XJ650 Maxim and Midnight Maxim, XJ650RJ Seca, 1982 XJ650 Turbo, XJ750-P (24L model), and all XJ750 Maxim and Midnight Maxim. Comes packaged as a pair of seals, enough to do both forks.
    $ 22.95

    HCP20112 Aftermarket premium quality lower fork tube BLACK OIL SEALS, fits all of the following models: XJ550 Maxim, FJ600, all XJ650 Euro models, XJ650 Maxim and Midnight Maxim, XJ650RJ Seca, 1982 XJ650 Turbo, XJ750-P (24L model), and all XJ750 Maxim and Midnight Maxim. NOTE: these seals feature a specially design lip and spring tensions that result in a much lower sliding friction between the seal and the fork tube. Comes packaged as a pair of seals, enough to do both forks.
    $ 32.95



    Oil Seal Retaining Clips:

    HCP1827 OEM lower fork tube OIL SEAL RETAINING CLIP, fits either left or right tube on the following models: all XJ550 models, FJ600, all XJ650 Euro models, XJ650 Maxim and Midnight Maxim, XJ650RJ Seca, 1982 XJ650 Turbo, XJ750-P (24L model), and all XJ750 Maxim and Midnight Maxim models. One clip does one tube. Highly recommended that these be replaced when replacing your oil seals! Each:
    $ 9.95

    HCP20716 Aftermarket lower fork tube OIL SEAL RETAINING CLIP, fits either left or right tube on the following models: all XJ550 models, FJ600, all XJ650 Euro models, XJ650 Maxim and Midnight Maxim, XJ650RJ Seca, 1982 XJ650 Turbo, XJ750-P (24L model), and all XJ750 Maxim and Midnight Maxim models. One clip does one tube. Highly recommended that these be replaced when replacing your oil seals! Each:
    $ 6.95



    Oil Seal Spacer Washer:

    HCP19997 OEM lower fork tube OIL SEAL SPACER WASHER, fits either left or right tube on the following models: all 1984-85 FJ600 models. One washer does one tube. This washer goes below the oil seal, and above the metal slider bushing! Each:
    $ 8.95

    HCP19997SET2 OEM lower fork tube OIL SEAL SPACER WASHERS, one pair does both forks.
    $ 16.95



    Lower Tube Metal Slider Bushings:

    HCP19996 OEM lower fork tube METAL SLIDE BUSHING, fits either left or right lower tube on the following models: all XJ550 Maxim, 1984-85 FJ600, XJ650RJ Seca, 1982 XJ650 Turbo, XJ750P (24L models), XJ750RL (44X Canadian model), and 1983 XJ750 Maxim and Midnight Maxim models. One slider does one tube. Each:
    $ 24.95

    HCP19996SET2 OEM lower fork tube METAL SLIDE BUSHINGS, set of 2:
    $ 47.95


    HCP10706 Aftermarket lower fork tube METAL SLIDE BUSHING, fits either left or right lower tube on the following models: all XJ550 Maxim, 1984-85 FJ600, XJ650RJ Seca, 1982 XJ650 Turbo, XJ750P (24L models), XJ750RL (44X Canadian model), and 1983 XJ750 Maxim and Midnight Maxim models. One slider does one tube. Each:
    $ 19.95

    HCP10706SET2 Aftermarket lower fork tube METAL SLIDE BUSHINGS, set of 2:
    $ 37.95



    Lower Fork Tube Oil Drain Screw and Gasket:

    HCP5187 OEM lower fork tube oil DRAIN SCREW, use one per tube. Natural finish, was originally black on models with black tubes. Fits all XJ-series bikes (except XJ1100 models) and all XS1100 Standard models. Each:
    $ 1.95

    HCP6708 Aftermarket lower fork tube oil DRAIN SCREW, use one per tube, panhead phillips-drive zinc-plated alloy steel. Fits all XJ-series bikes (except XJ1100 models) and all XS1100 Standard models. Each:
    $ 0.95

    HCP6709 Aftermarket lower fork tube oil DRAIN SCREW, use one per tube, panhead phillips-drive 18-8 stainless steel, bright finish. Fits all XJ-series bikes (except XJ1100 models) and all XS1100 Standard models. Each:
    $ 1.00

    HCP6710 Aftermarket lower fork tube oil DRAIN SCREW, use one per tube, panhead phillips-drive 18-8 stainless steel, black-oxide coated finish. Fits all XJ-series bikes (except XJ1100 models) and all XS1100 Standard models. Each:
    $ 1.25

    HCP6712 Aftermarket lower fork tube oil DRAIN SCREW, use one per tube, socket head cap screw, hex-drive, 18-8 stainless steel, bright finish. Fits all XJ-series bikes (except XJ1100 models) and all XS1100 Standard models. Each:
    $ 1.00

    HCP6711 Aftermarket lower fork tube oil DRAIN SCREW, use one per tube, socket head cap screw, hex-drive, black-oxide coated finish. Fits all XJ-series bikes (except XJ1100 models) and all XS1100 Standard models. Each:
    $ 1.00


    HCP7111 OEM lower fork tube oil drain screw GASKET, use one per tube. Fits all XJ-series bikes (except XJ1100 models) and all XS1100 Standard models. Each:
    $ 1.95

    HCP21320 Aftermarket lower fork tube oil drain screw GASKET, use one per tube. Fits all XJ-series bikes (except XJ1100 models) and all XS1100 Standard models. Each:
    $ 1.50

    HCP21320SET2 Aftermarket lower fork tube oil drain screw GASKET, use one per tube. Fits all XJ-series bikes (except XJ1100 models) and all XS1100 Standard models. Per pair:
    $ 2.95



    Lower Fork Tube Damper Rod Retaining Bolt and Gasket:

    HCP8233 OEM fork tube damper rod RETAINING SCREW. For all XJ550, 1984-85 FJ600, 1992-98 XJ600 Seca II, XJ650, XJ700, XJ750 (except 1981-83 XJ750 Seca or XJ750 Euro), XJ750RL, XJ900, and XS1100 Standard models. Use 1 per tube. Each:
    $ 6.95

    HCP12949 Aftermarket fork tube damper rod RETAINING SCREW. For all XJ550, 1984-85 FJ600, 1992-98 XJ600 Seca II, XJ650, XJ700, XJ750 (except 1981-83 XJ750 Seca or XJ750 Euro), XJ750RL, XJ900, and XS1100 Standard models. Use 1 per tube. Each:
    $ 4.95

    HCP8234 OEM fork tube damper rod retaining screw copper crush washer GASKET. For all XJ550, 1984-85 FJ600, 1992-98 XJ600 Seca II, XJ650, XJ700, XJ750 (except 1981-83 XJ750 Seca or XJ750 Euro), XJ750RL, XJ900, and XS1100 Standard models. Use 1 per tube. Each:
    $ 9.50

    HCP12950 Aftermarket fork tube damper rod retaining screw copper crush washer GASKET. For all XJ550, 1984-85 FJ600, 1992-98 XJ600 Seca II, XJ650, XJ700, XJ750 (except 1981-83 XJ750 Seca or XJ750 Euro), XJ750RL, XJ900, and XS1100 Standard models. Use 1 per tube. Each:
    $ 6.95


    w) Lower Fork Tube DAMPER ROD RETAINING TOOL. This long aluminum tool, with proper sized nuts on each end, is used to retain the top of the fork damper rod (in the bottom of the chrome tube) when removing or installing the damper rod retaining screw. One end has a 19mm hex and the other end has a 22mm hex, so it will fit all styles of XJ-series bikes except XJ600 Seca II, 1981-83 XJ750 Seca, XJ1100, and all XS1100 Special and Midnight Special models. This tool will make the disassembly of your upper tube from the lower tube much easier! NOTE: this tool is available for short term rental, please see the “rental” section within the THE TOOLBOX section of our catalog at:

    http://xjbikes.com/forums/index.php?threads/xj-parts-catalog-section-p-the-toolbox.44630

    and review the availability and procedures in the TOOL RENTAL section.

    HCP4402 Aftermarket DAMPER ROD RETAINING TOOL.
    $ 29.95



    Fork Tube Brace and Hardware:

    HCP8480 OEM lower fork tube brace RETAINING BOLT, use 2 per tube (4 per bike) on both the left and right side lower fork tube. Bright finish, alloy steel socket head, allen-drive. For all FJ600, XJ750RL, and XJ900RK, RL, N/FN, and F models. Each:
    $ 2.25

    HCP2424 Aftermarket lower fork tube brace RETAINING BOLT, use 2 per tube (4 per bike) on both the left and right side lower fork tube. Black oxide coated alloy steel socket head, allen-drive. For all FJ600, XJ750RL, and XJ900RK, RL, N/FN, and F models. Each:
    $ 1.95

    HCP80 Aftermarket lower fork tube brace RETAINING BOLT, use 2 per tube (4 per bike) on both the left and right side lower fork tube. Black oxide coated alloy steel socket head, allen-drive. Features a small nylon thread patch, making this a self-locking bolt. For all FJ600, XJ750RL, and XJ900RK, RL, N/FN, and F models. Each:
    $ 1.95

    HCP2423 Aftermarket lower fork tube brace RETAINING BOLT, use 2 per tube (4 per bike) on both the left and right side lower fork tube. Bright 18-8 stainless steel socket head, allen-drive. For all FJ600, XJ750RL, and XJ900RK, RL, N/FN, and F models. Each:
    $ 1.50



    Lower Fork Tube Axle Retaining Hardware:

    HCP4828 OEM front axle shaft-to-lower tube RETAINING BOLT, use 1 per tube (2 per bike) on both the left and right side lower fork tube. For all XJ550 Seca, 1984-85 FJ600, all XJ650 Euro models, XJ650RJ Seca and XJ650 Turbo models, XJ750RL, XJ750P (37H model), and XJ900RK, RL, N/FN, and F models. Each:
    $ 2.95



    HCP2537 OEM front axle shaft-to-lower tube retaining bolt FLAT WASHER, alloy steel, bright finish, for all 1981 XJ550 Seca models, 1984-85 FJ600, all XJ650 Euro models, XJ650RJ Seca and XJ650 Turbo models, XJ750RL, XJ750P (37H model), XJ700-X and XJ750-X models, XJ900RK, RL, N/FN, and F models. Use 2 per retaining bolt (4 per bike) on both the left and right side lower fork tubes. NOTE: XJ700-X and XJ750-X models only use 1 of the washers per bike).
    $ 1.95

    HCP26192 Aftermarket front axle shaft-to-lower tube retaining bolt FLAT WASHER, alloy steel, bright finish, for all XJ550 Seca models, 1984-85 FJ600, all XJ650 Euro models, XJ650RJ Seca and XJ650 Turbo models, XJ750RL, XJ750P (37H model), XJ700-X and XJ750-X models, XJ900RK, RL, N/FN, and F models. Use 2 per retaining bolt (4 per bike) on both the left and right side lower fork tubes. NOTE: XJ700-X and XJ750-X models only use 1 of the washers per bike). Each:
    $ 0.95

    HCP26193 Aftermarket front axle shaft-to-lower tube retaining bolt FLAT WASHER, 18/8 stainless steel, bright finish, for all XJ550 Seca models, 1984-85 FJ600, all XJ650 Euro models, XJ650RJ Seca and XJ650 Turbo models, XJ750RL, XJ750P (37H model), XJ700-X and XJ750-X models, XJ900RK, RL, N/FN, and F models. Use 2 per retaining bolt (4 per bike) on both the left and right side lower fork tubes. NOTE: XJ700-X and XJ750-X models only use 1 of the washers per bike). Each:
    $ 1.25

    HCP17110 Aftermarket front axle shaft-to-lower tube retaining bolt FLAT WASHER, 316 stainless steel, dull finish, for all XJ550 Seca models, 1984-85 FJ600, all XJ650 Euro models, XJ650RJ Seca and XJ650 Turbo models, XJ750RL, XJ750P (37H model), XJ700-X and XJ750-X models, XJ900RK, RL, N/FN, and F models. Use 2 per retaining bolt (4 per bike) on both the left and right side lower fork tubes. NOTE: XJ700-X and XJ750-X models only use 1 of the washers per bike). Each:
    $ 1.95

    HCP26189 Aftermarket front axle shaft-to-lower tube retaining bolt FLAT WASHER, alloy steel, black finish, for all XJ550 Seca models, 1984-85 FJ600, all XJ650 Euro models, XJ650RJ Seca and XJ650 Turbo models, XJ750RL, XJ750P (37H model), XJ700-X and XJ750-X models, XJ900RK, RL, N/FN, and F models. Use 2 per retaining bolt (4 per bike) on both the left and right side lower fork tubes. NOTE: XJ700-X and XJ750-X models only use 1 of the washers per bike). Each:
    $ 2.95



    HCP2185 OEM front axle shaft-to-lower tube retaining bolt LOCK WASHER, use 1 per bike on the following models: all XJ550 Maxim models, 1984-85 FJ600, all XJ650 Maxim models, all XJ700 models, all 1982-83 XJ750 Maxim models, XJ750-X, and XJ1100 models. Use 2 per bike on the following models: all 1981 XJ550 Seca, all XJ650 Euro models, XJ650RJ Seca and XJ650 Turbo models, XJ750-D, XJ750P (37H model), and XJ900RK, RL, and F models. Each:
    $ 1.95

    HCP16209 Aftermarket front axle shaft-to-lower tube retaining bolt LOCK WASHER, zinc-plated alloy steel, use 1 per bike on the following models: all XJ550 Maxim models, 1984-85 FJ600, all XJ650 Maxim models, all XJ700 models, all 1982-83 XJ750 Maxim models, XJ750-X, and XJ1100 models. Use 2 per bike on the following models: all 1981 XJ550 Seca, all XJ650 Euro models, XJ650RJ Seca and XJ650 Turbo models, XJ750-D, XJ750P (37H model), and XJ900RK, RL, and F models. Each:
    $ 0.95

    HCP16100 Aftermarket front axle shaft-to-lower tube retaining bolt LOCK WASHER, 18-8 stainless-steel with a bright finish, use 1 per bike on the following models: all XJ550 Maxim models, 1984-85 FJ600, all XJ650 Maxim models, all XJ700 models, all 1982-83 XJ750 Maxim models, XJ750-X, and XJ1100 models. Use 2 per bike on the following models: all 1981 XJ550 Seca, all XJ650 Euro models, XJ650RJ Seca and XJ650 Turbo models, XJ750-D, XJ750P (37H model), and XJ900RK, RL, and F models. Each:
    $ 0.95

    HCP16102 Aftermarket front axle shaft-to-lower tube retaining bolt LOCK WASHER, black-oxide coated finish, use 1 per bike on the following models: all XJ550 Maxim models, 1984-85 FJ600, all XJ650 Maxim models, all XJ700 models, all 1982-83 XJ750 Maxim models, XJ750-X, and XJ1100 models. Use 2 per bike on the following models: all 1981 XJ550 Seca, all XJ650 Euro models, XJ650RJ Seca and XJ650 Turbo models, XJ750-D, XJ750P (37H model), and XJ900RK, RL, and F models. Each:
    $ 0.95



    HCP3494 OEM front axle shaft-to-lower tube retaining bolt NUT, use 1 per bike on the following models: all XJ550 Maxim models, all XJ650 (except Midnight Maxim) models, all XJ700 non-X models, all 1982-83 XJ750 Maxim, XJ750-D, and XJ1100 models. Use 2 per bike on the following models: all XJ550 Seca, 1984-85 FJ600, all XJ650 Euro models, XJ750RL, all XJ900RK, RL, N/FN, and F models, and 1979 XS1100 Special models. Each:
    $ 3.95

    HCP24037 Aftermarket front axle shaft-to-lower tube retaining bolt NUT, made from 18/8 stainless steel, use 1 per bike on the following models: all XJ550 Maxim models, all XJ650 (except Midnight Maxim) models, all XJ700 non-X models, all 1982-83 XJ750 Maxim, XJ750-D, and XJ1100 models. Use 2 per bike on the following models: all XJ550 Seca, 1984-85 FJ600, all XJ650 Euro models, XJ750RL, all XJ900RK, RL, N/FN, and F models, and 1979 XS1100 Special models. Each:
    $ 2.95



    FORK SYSTEM SERVICE TOOLS:

    Assembly and Dis-assembly Tools:

    NOTE: many of these tools are available for short term rental, please see the “rental” section within the THE TOOLBOX section of our catalog at:

    http://xjbikes.com/forums/index.php?threads/xj-parts-catalog-section-p-the-toolbox.44630

    and review the availability and procedures in the TOOL RENTAL section.


    w) Lower Fork Tube DAMPER ROD RETAINING TOOL. This long aluminum tool, with proper sized nuts on each end, is used to retain the top of the fork damper rod (in the bottom of the chrome tube) when removing or installing the damper rod retaining screw. One end has a 19mm hex and the other end has a 22mm hex, so it will fit all styles of XJ-series bikes except XJ600 Seca II, 1981-83 XJ750 Seca, XJ1100, and all XS1100 Special and Midnight Special models. This tool will make the disassembly of your upper tube from the lower tube much easier!

    HCP4402 Aftermarket DAMPER ROD RETAINING TOOL.
    $ 29.95


    HCP9238 Aftermarket fork upper cap bolt REVERSE HEX SOCKET TOOL. This tool allows the easy removal and installation of the "inverted/reversed" hex-drive cap bolt used on the top of the inner fork tubes on all 1984 FJ600, XJ650 Turbo, XJ700 non-X, XJ750-D, XJ750P (37H) model, and all XJ900RK, RL, N/FN, and F models.
    $ 12.95

    HCP15939 Aftermarket lower fork tube OIL SEAL DRIVER. split “clamshell” heavy duty design features adjustable inserts that allow it to be used properly and safely install the lower tube oil seals and (where applicable) lower tube dust seals on all 35-43mm fork tubes (which covers the entire XJ- and XS-series line of bikes).
    $ 39.95



    Super-Penetrant Fluids and Lubricants:

    Sometimes, the toughest part of working on a vehicle is battling the effects of time: seized fasteners, caused by rust, corrosion, and other factors, turns what should be a 5-minute effort into a 50-minute (or more) chore, complete with rounded-off, ruined, or snapped fasteners, e-z outs, heli-coil inserts, and more.........and that's just not right.

    While the proper use of our various Anti-Seize products will prevent these nightmares from occurring in the future, you're stuck in the here-and-now, and the best way to handle these obstacles is to have the proper tools at the stand-by; and in the case of fastener seizure, the proper "tool" is a can or two of our SUPER PENETRATING LUBRICANTS at the ready; a couple of squirts, a little bit of time-----perhaps some heat for those really nasty situations----and you're on your way again, hopefully not too much worse for the experience.....

    Great for use on all fasteners, fork tube cap bolts, intake and exhaust manifolds bolts, studs, and nuts, lock cylinder tumblers, or anywhere an un-cooperative fastener can be found. Can even be used to help un-seize frozen engines!

    Be aware that these products are not your typical, garden-variety, run-of-the-mill "retail" type products; these are designed an used as industrial- and military-strength products, meaning they have special formulations that include a dollop more of the "good stuff" within them to solve the toughest seizure problems imaginable (the "good stuff" ingredients cost more, and it is those compounds that are left out of or reduced in concentration in "retail" level consumer products).

    NOTE: the following product(s) can only be shipped via ground transport (which thus eliminates the Priority Mail level of service for this item) and cannot (and will not----don't even ask!) be shipped outside of the continental USA. Therefore it may have to be shipped in a separate package from the remainder of your order, and will thus incur additional shipping charges.

    HCP10331 Aftermarket standard-duty PENETRATING LUBRICANT, in a generous 16-ounce aerosol can. Oil-based lubricant penetrates down into spaces of one-millionth of an inch to handle the most reluctant seizures. Actually dissolves the rust and corrosion that causes the seizure; lubricates and displaces moisture to prevent rust re-formation. This product is what we use and recommend for freeing stuck fork tube cap bolts and other such challenging fasteners.
    $ 24.95

    HCP11974 Aftermarket super-duty PENETRATING LUBRICANT, in a generous 13-ounce aerosol can. Same as our standard-duty formula above, but also includes graphite to not only enhance and speed up the penetrant action, but also gets down into the pores of the metal for the greatest possible lubrication possible. The cat's-meow of penetrating fluids, can even be used to un-seize frozen engines or as an engine assembly lube! This fluid is also a great choice for use as a drive cable lubricant.
    $ 26.95

    HCP10333 Aftermarket extreme-duty PENETRATING LUBRICANT, in a generous 16-ounce aerosol can. Same as our standard-duty formula above, but also includes liquid silicone to enhance and speed up the penetrant action. This product is also an exceptional choice for use as a control-cable lubricant.
    $ 27.95



    Assembly Fluids and Lubricants:

    NOTE: the following product(s) can only be shipped via ground transport (which thus eliminates the Priority Mail level of service for this item) and cannot (and will not----don't even ask!) be shipped outside of the continental USA. Therefore it may have to be shipped in a separate package from the remainder of your order, and will thus incur additional shipping charges.

    HCP20860 Aftermarket industrial-strength ASSEMBLY LUBE, in a standard 12-ounce aerosol can. Heavy-duty formula includes graphite to not only enhance and speed up the penetrant action, but also gets down into the pores of the metal for the greatest possible lubrication possible. Won't wash away, protect against rust and corrosion, stable from 0-degrees up to 250-F. This fluid is also a great choice for use as a drive cable lubricant.
    $ 21.95

    HCP20862 Aftermarket super-duty ASSEMBLY LUBE, in a generous 10-ounce aerosol can. The cat's-meow of lubricants, infused with pure moly disulfide, it goes on wet and then dries in 1-2 hours to a super-slick, high-pressure, hi-temp, bearing-like finish which provides the ultimate level of protection. Prevents rust and corrosion, won't wash off, throw off, and won't attract dust or dirt. Surfaces must be clean and dry of previous oils, etc. before application. Can even be used as an engine, tranny, and drivetrain assembly lube!
    $ 24.95

    HCP20863 Aftermarket super-duty GRAPHITE LUBE, in a generous 10-ounce aerosol can. The 800-pound gorilla of lubricants, it's infused with pure graphite, goes on wet, and then dries in 10 minutes to a super-slick, high-pressure, bearing-like finish which provides the ultimate level of protection. Prevents rust, won't wash off, throw off, and won't attract dust or dirt. Surfaces must be clean and dry of previous oils, etc. before application. Can be used as an engine assembly lube, bearing or bushing pre-lube, great for lock cylinders, and all metallic sliding surfaces. Use where dusty or dirty conditions render oil-based lubricants ineffective or undesirable.
    $ 21.95



    Fork Tube Cleaning and Polishing:

    HCP9208 Fork Tube DEEP REACH CLEANING BRUSH. This 30" long handled brush features vinyl-covered wires that can reach deep inside the forks tubes to clean away grit and oil sludge residue that cannot otherwise be reached or disturbed. Use with your favorite cleaning solvents to get the insides of the fork tubes free of contaminants.
    $ discontinued


    ft4) These stainless-steel, bristle-wire DE-BURRING BRUSHES will work wonders on the upper cap bolt area on both the threaded and the non-threaded style of fork tubes. Tubes that use threaded cap bolt (all XJ650 Turbo, all XJ700 models, XJ750-X models, XJ750 Maxim and Midnight Maxim, XJ900RK, and XJ1100 models) should use the HCP10223 butterfly brush; non-threaded tubes can use either the HCP10222 spiral brush or the HCP10223 butterfly brush. Both style brushes have stems that are designed to be used in a standard power drill, and should be used at 850 rpm's or less. These brushes will make quick and meaningful work of the cleaning and polishing of this critical area on your upper fork tubes.

    HCP10222 Aftermarket stainless-steel double-density spiral DE-BURRING BRUSH, for use on fork tubes without a threaded cap bolt.
    $ 8.25

    HCP10223 Aftermarket stainless-steel high-density "butterfly-wings" DE-BURRING BRUSH, for use on fork tubes with or without threaded cap bolts.
    $ 8.25



    Fork Tube Oil Level Gauges:

    HCP1728 Fork tube oil fluid level measurement GAUGE AND SYRINGE. This handy tool makes the measurement of the fork oil level easy and accurate. NOTE: the proper amount of fork oil is determined via the measurement of the fork oil LEVEL (distance below the very top of the inner tube) rather than a volume AMOUNT of oil specification. Too little oil will make the ride mushy, while too much oil makes the ride harsh (and can blow out the oil seals!)
    $ 29.95



    ffl4) Aftermarket fork oil measurement GRADUATED CYLINDERS. The best way to measure the precise amount of fork oil fluid is via the use of these lab-quality measurement cylinders. Available in either transparent (clear) or translucent (cloudy) durable plastic construction, they all have easy-to-read scale numerals (milliliters) and feature a "non-wetting" inner surface coating that prevents the concave "meniscus" from forming at the top of the fluid, thus insuring a much more accurate level reading. Large bases insure stability while large spouts make "the pour" easy and prevent messy drips. Very useful device to have for front fork oil changes.

    HCP10741 Aftermarket fork oil GRADUATED CYLINDER, 250ml capacity, translucent (cloudy).
    $ 11.95

    HCP10744 Aftermarket fork oil GRADUATED CYLINDER, 250ml capacity, transparent (clear).
    $ 24.95

    HCP10742 Aftermarket fork oil GRADUATED CYLINDER, 500ml capacity, translucent (cloudy).
    $ 12.95

    HCP10745 Aftermarket fork oil GRADUATED CYLINDER, 500ml capacity, transparent (clear).
    $ 33.95

    HCP10743 Aftermarket fork oil GRADUATED CYLINDER, super-sized 1000ml capacity, translucent (cloudy), with convenient side handle to insure steady pouring.
    $ 48.95



    Fork Tube Air Pressure Tool and Gauge:

    HCP9196 Aftermarket AIR VALVE STEM TOOL, handy 4-in-1 tool allows you to properly remove and insert the stem core, and also clean/chase/re-thread the internal and external stem threads.
    $ 4.95

    HCP9108 Aftermarket air-assisted forks LOW PRESSURE AIR GAUGE, heavy-duty 0-20 psi pencil (stick) pressure gauge marked in 1/2-psi increments, perfect for checking fork air pressures on models so equipped. Very high quality and much more accurate than standard tire pressure gauges, which is very important on the fork pressures as an imbalance between the fork pressure can lead to steering and stability issues, while too much pressure will blow out the lower tube oil seals!
    $ 4.95
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