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Replace Your Fork Seals
How To - Suspension Tuning
Written by matt   

You’ve heard it before, but I’ll say it again.  It’s always best to start with a clean motorcycle.  So spray the thing off, clean your work area, then get started.  Changing the fork seals almost always results in a mess, so be prepared to be assaulted by copious amounts of fork oil.  This job is best done with your spouse visiting family, because things usually do get messy.

 

 

  • Remove the front wheel, then the forks.
  • Remove the large top fork cap and dump the oil.  There are special tools made by Motion Pro and others that are specifically designed for the fork top cap.  A large crescent wrench also works.
  • Replace the top cap.
  • Now loosen the rebound nut.  Most people find it easiest to clamp your fork in a vice (usually with a piece of wood to protect the outer fork tube) to keep the fork from spinning.
  • Now compress the fork tubes together, this will cause the damper rod to groundhog (poke) out the bottom.
  • With the damper rode poking out, take a 12mm wrench and use it to keep the tubes from extending.
  • Now remove the rebound adjuster nut from the damper rod.
  • With the rebound adjuster removed, compress the fork tubes together and remove your 12mm wrench from the damper rod.
  • While the fork is compressed, remove the big cap and pull the damper out.  Try to not let the spring fall out of the fork.
  • To replace the seals, use a screw driver and pry the off dust cover on the seal.
  • Now remove the retaining clip with a screw and driver needle nose pliers.
  • Next you slide the fork apart with some force.

Reverse the process to assemble the forks back together.  To install new seals make sure you use a plastic bag over the fork end when sliding on the new seals.
Last Updated ( Sunday, 09 July 2006 )
 
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