‘81 - ‘83 Virago XV750 Fork Seal Replacement

DIY for replacing the fork seals for a 1st Generation ('81 - '83) XV750 Virago. Also shows how to remove the inner slide when it will not break free from the bottom bolt

[@---tf4vu]

Yet again Steve saves the day. I've got a Clymer manual and a Haynes manual, but get far more information from Steve's DIYs. My bike has been sitting for about 27 years. When I finally got the tops of the forks off it seems there was no oil left inside. Maybe it evaporated. My bike is an XV920R, so the forks are slightly different with the bolts recessed. Anyway, those bolts at the bottom would not budge. Two days of trying various ideas but nothing would shift them. Ended up bolting the fork legs to a large plank of wood, and then clamping that to a table in the yard. Breaker bar and a rubber mallet finally got the bolts rotating, but then had to use the broomstick method to get them loose from the internals. A real sense of euphoria when it works out. Thanks, Steve.

[@StevesDIYs]

Thanks and glad the video helped some 👍. Yep, these can be real pains to get taken apart as the forks hardly ever get serviced on bikes…might have been the first time they were ever apart lol. Sounds like you got it though which, like you said, always gives a deal of satisfaction to finally get a tougher job done. All the best ! Steve.

[@johnrickinger8861]

Dude...you're a lifesaver. That trick with the dowel worked perfect. My '82 750 is back in shape!

[@StevesDIYs]

Thanks man ! Glad the video helped some 👍. Yep, Every time I took them apart do the seals in the past I said I’m gonna measure the bolt head and then make a tool, but never do, ha, ha. I can always find a broom handle laying around, but would probably forget where I put the tool if I made one the next time I redid the seals, lol. All the best ! Steve

[@RedMo46]

Left fork leaking all over the rotor. Exactly the same boat Im in. My tires started to cup too as a result. Though, the sidewall is cracking as well so it was overdue anyways. Appreciate you makin all these videos my man, brilliant resource and a huge help✌️

[@StevesDIYs]

Thanks ! Glad the videos have helped some 👍. Yep, my 2nd Gen is due up as well it seems as I just noticed a puddle on the left side yesterday up by the front tire. They seem to last for years and then all of a sudden they just start leaking unfortunately. I may have to make another video for the 2nd Gen as well, lol (probably about the same as the 1st Gen though ). Thanks again and all the best ! Steve

[@alexshepherd4469]

Thanks for sharing this. I just followed your video to replace the fork oil in my 82 Virago 750. Mine was pretty rusty so it took a rubber mallet and socket plus lots of WD40...

[@StevesDIYs]

Alex Shepherd , thanks man ! Glad it was helpful 👍

[@rjx1083]

hello mr. steve is this the same to removed 535 virago ?

[@StevesDIYs]

Hey ! If the 535 has plastic caps on top of the fork tubes that can be removed and the retaining clips beneath the plastic caps I would think the design is mostly the same so it should be similar. I’m not 100% sure though as I do not have a xv535, but that would be an easy way to check to see if the design is the same. All the best ! Steve

[@alexshepherd4469]

@@rjx1083 www.yamahapartshouse.com/oemparts/a/yam/50042242f8700209bc7875a2/front-fork check the part blow up to confirm

[@thomasm9384]

Colder than a well digger's chicken. Thanks for the help, buddy!

[@StevesDIYs]

Thanks man ! Yep, it was cold out in the garage that day for sure, lol. All the best ! Steve

[@amcgarry68]

Love the style of that 750 man i have a 88

[@StevesDIYs]

Thanks man ! That’s the bobber I did a year or so ago...definitely gets more looks than the stock bike, but the stock one has it beat for comfort for longer rides, lol. All the best ! Steve

[@MrUND3RSC0R3]

Hey hoping you might still be active. I have a xv500 just like this, got the forks off and torn apart down to the oil seal itself, its really rusted in there and the rubber disintegrated, the oil has been held in by rust basically. What advice may you have on removing it to replace it?

[@StevesDIYs]

Hello, there should be a thin wire clip holding the oil seal in, but if it is all rusty on top of the seal, it has probably mostly rusted away. The metal wire clip is actually where all of the rust came from since the fork tubes are stainless and the fork bodies are aluminum. You’ll have to take a small pick and feel around on top of the fork seal to clean the rust and remaining parts of the wire retaining clip away until you can see the groove that goes around the fork body just above the seal. Once that’s all cleaned out, you should be able to pry what’s left of the old seal out with a screwdriver being careful not to damage the top of the fork body when you pry against it. Hope this helps a bit and let me know how it goes 👍, Steve

[@MrUND3RSC0R3]

@@StevesDIYs Heya thanks, I did have the clip out, ended up taking my frustration out on it and just hammered a flathead between the seal and leg and luckily the seal gave way before any damage to the leg, and could then pry under the damaged seal and get it out. Second one took seconds, wish I went that method before prying on it from inside the seal over an hour

[@StevesDIYs]

@@MrUND3RSC0R3 Hey again ! Sounds like that works too as an option so good to know 👍. I would have been worried a bit that it would have damaged the fork body, but sounds like it worked much easier. Glad you got it headed in the right direction and all the best ! Steve

[@briandeguire7097]

Steve, great video. Is the procedure basically the same for an ‘88 1100 virago ?? Hope to hear from you soon. Thanks, Brian

[@StevesDIYs]

Thanks man ! Yes, it’s basically the same except that the 2nd Gens have a huge hex nut on top vs. the wire clip and the top tube won’t just slide out (more on that below). I have an ‘88 1100 as well and the top hex nuts were rusted solid (and stripped out as well from the previous owner) so I couldn’t get them off to put something down the tubes like the wooden broom handle to hold the top of the bolt. I ended up ratchet strapping the bottom of the shock up tight to get the bottom bolt out then they came apart. There is one difference internally…on the 2nd Gens there is a larger diameter ring inside that prevents the shock from coming apart without first removing the seal clip and the seal. I believe it was a safety feature addition as the 1st Gens will separate completely if the bottom bolt is removed, but this added ring prevents the 2nd Gens from doing that. You’ll first have to remove the bottom bolt, then slide up the dust seal, then remove the seal clip made of wire that holds the seal in. Then you can pull down real hard (like a slide hammer) on the bottom of the shock portion (be sure the seal clip is removed) and it will pop the seal out. Then it just goes back in reverse order 👍. I actually did a video of me doing mine (and dealing with the stripped out top hex nut, lol), but I haven’t edited it to load to the channel. I’ll see if I can do that and get it on the channel tomorrow so you can see if you aren’t doing your today 👍.

[@briandeguire7097]

Thank you for responding. Will be watching for the video. Thanks again, Brian

[@KamiloSdar]

Thank You

[@StevesDIYs]

Thanks man ! Glad the video helped some 👍. All the best ! Steve

[@betoobox]

Thanks for all your videos, im super fan! haha. How do you hold the bolt when is time to reassembly? whit de wood stick?

[@StevesDIYs]

Thanks man ! Glad the videos help out some with these cool old bikes 👍. Yep, to hold the inner slide for reassembly I just tap the wood stick in and then tighten the bolt...giving it a whack with a hammer once it’s pretty tight to be sure it compresses the seal washer under the bolt head. It usually gets the wood stick oily and damaged from doing the first shock so I just cut the end off and taper it again so there is a fresh end on the stick for the 2nd shock. Once you take the first one out you can see the shape of the end of the inner slide so you could make a better tool than the stick for the next shock, but since it’s not often that I have had to replace the seals, I’d probably forget where I put the tool 5 years from now and would have to use a stick again 🤣🤣🤣. All the best !! , Steve

[@betoobox]

@@StevesDIYs yes, thats what im thinking, make an tool on metal for future maintenence. Actually searching i see you can use an 19mm head bolt and suppose it will work. im gona try and post here, maybe can help someone. Thanks again!

[@donjuilogulfcitybikertrash1209]

I have to repair my forks on my virago. What type of oil do I need to use?

[@StevesDIYs]

Don Keedik Gulf city Biker & Trash Man , hey man...the book calls out for SAE 10W for the Gen 1’s, so I’ve always just used 10W-30 conventional. Hope this helps, Steve

[@Thumperwrestler]

What size PVC pipe to get in there?

[@StevesDIYs]

Hey man ! The PVC size is 1-1/2” schedule 40 to thump the seal back in place. All the best ! Steve

[@Thumperwrestler]

@@StevesDIYs ok nice do you think it's the same size for 1997 virago 750 forks?

[@StevesDIYs]

@@Thumperwrestler hey again. Yes, I believe all of the viragos had the same diameter fork tubes. I also did my ‘89 1100 and used the same piece of pvc that I did on my 1st Gen 750 👍

[@StevesDIYs]

@@Thumperwrestler I was just editing the video I did for the 1100 and realized that I also used a 1-1/4” pvc pipe joint below the 1-1/2” pvc pipe on the 2nd Gen as it fit the seal better. I should have that video posted this evening if you want to look for it in the xv1100 playlist. It was actually a big hassle on this bike as the top hex cap on my bike was stripped out so I had to do them from the bottoms, but if your top caps are still good it would be about the same as the first Gens (like this video 👍)

[@negrueugen7055]

Hi, how much oil goes into the fork? Thanks!

[@StevesDIYs]

Hello, for the First Gen (‘81-‘83) they take 278 cc’s (9.4 US fluid oz) of SAE 10w fork oil.

[@negrueugen7055]

@@StevesDIYs 278 milliliters?

[@negrueugen7055]

Virago XV 700"84!

[@StevesDIYs]

Negru Eugen , the ‘84 and ‘85 700’s have a different quantity than the 1st Gens. For yours, it takes 389 cc’s (or 389 milliliters) per the book. Hope this helps, Steve

[@negrueugen7055]

@@StevesDIYs thanks very Steve

[@codyhartley1537]

Did you use Yamaha seals or some other aftermarket?

[@StevesDIYs]

Cody Hartley hey man, I’ve always used All Balls Racing fork seals and dust wipers once I found them as they have an extra little spring on the outside of the dust seal to keep the rubber tight against the fork tubes (I used to do a lot of dirt riding and it was more critical for them, but I liked the idea even for street bikes). There are probably other good seals out there from different manufacturers (including the OE’s) so It’s not to say theirs are the best or anything, it’s just the brand I go to first if they have the ones for a bike I’m working on or rebuilding. I will say that I’ve never had to replace a set of theirs on any of the street bikes I’ve put them on. All the best, Steve

[@codyhartley1537]

Steve’s DIYs thanks man! I’ve used all balls for dirt bikes before just crossed my mind. Over the weekend I came across a 1 owner from California, 21k original miles midnight special that I plan on restoring. Carbs were gummed,form seals leaking, and a few other small odd and ends but all and all a beautiful bike has been sitting since 2012

[@StevesDIYs]

Cody Hartley , sounds like a nice one to restore for sure 👍. My stock ‘81 750 is the best riding bike I’ve had (I slowly got rid of all of the other makes and models, but never thought about selling the Virago. Just something about these old girls and their naturally noisy engines, over complicated carbs, and clunky starters that make them more than just hopping on a bike and going for a ride. Most of the time I congratulate mine after a long ride for not giving up...even after almost 40 years of being on the road 🤣🤣🤣. If you do get the bike and haven’t joined the “Virago Nation - all things Yamaha Virago” Facebook forum, join up and post some pics of it and then the progression as you restore it...it’s always great to see another Virago brought back to life and made pretty again...especially one of the Midnights 👍