is there a special tool for disassembling the fork tubes on a 1978 yamaha xs 11?

Question

the hex bolt spins but wont separate is there a way to hold the inside nut from spinning ??

Answer 1

yes there is a special tool, but you can make your own.you will need a nut that fits the hex bolt and a long bolt that you can weld to the nut,it's a simple tool and easy to make.

Answer 2

Doug,,have you got the fork tube caps off,,and springs out?

If So,,put them back in.

The spring pressure helps hold the damper tube in place.

The damper tube is actually what that allen bolt is threaded into.

There's no NUT inside.

"Special Tool" is a 2 piece deal.
Allen Socket & an air or electric impact wrench.

Do AT LEAST what Jim said,,,,that's probly a 95% ++ sure-fire solution.
Most will come apart that way.
But Do it with the Springs IN the Fork & the Caps on...to Hold the damper from turning.

It does Not hold it SOLID,,,but introduces a Very Large degree of Friction to keep it from turning.

When all else fails,,,Power Impact Wrench's Speed and abrupt acceleration will get it out

.................................
Here's a Picture(it should have Zoom button appear)

http://parts.yamaha-motor.com/partimage.gifx?d=29326,3,0

You're after Bolt # 27.

See the lil' necked-down nose on Item #11???
Thats what the bolt is screwed in to--"Damper Rod"
Or according to Yamaha>
"11 2H7-23170-00-00 CYLINDER COMP., FRONT FORK "

Note Directly at Other end of #11 is #12>>Fork Spring.
When Spring is in place,,it helps a BUNCH to "hold" the #11 from spinning

***Dont worry about Unscrewing the #27 Bolt while Fork Leg is under Spring Tension & crap flying apart.

that WILL NOT Happen.

The Damper Tube is hed Captive within the Fork Tube by a Shoulder at bottom of Leg.

It must come out the TOP after spring is removed,,it cannot come out the bottom.

If worse comes to worst,,,slide the legs outa the triple clamps and take them ANYWHERE that has an air wrench.
Gas Station service bay,,tire store,etc.
Most those guys will zap the bolts out for you on-the-spot.
For "six-pack money",,if they take anything at all.
BRING your Allen Socket with You,,,many places wont have correct one.

Usually once you get them broke free(via the GuardrdrailJim Plan),,,they come out very easy,,IF ya got the springs in to help hold it

Good Luck with it

Answer 3

The bolt is installed with locktite.
Do not try to remove it with an allen wrench - use an allen bit on a socket.
http://www.snapon.com/
Search for - socket driver - 3/8" Drive
Insert the socket into the allen bolt and SLAM it a few times with a metal hammer - this will break loose the locktite.
Then remove the bolt with a hand held impact wrench.
http://www.powersportrider.com/CGI-BIN/ZCATJPG?catalog=ST0206C
Pick - Street Catalog
Go to - Index - Tools - Bike Master - pg 919 - Impact Driver

Answer 4

Take the C- clip out of the top of the fork slider and just compress and pop it off.If you cannot get the bottom allen bolt tight u may have to have the bike shop do it or it will leak.

Answer 5

push a wood dowel rod down the tube to find out what size allen wrench you need, weld a bolt with that size head or an allen wrench to a piece of re bar long enough to reach the bottom of the tube, you can hold the re bar with vise grips or bend the re bar at a right angle to make a handle. paint it red or yellow so you can find it next time you need it,