Fork seal replacement

[Nubian]

I will be undertaking the task of rebuilding my forks. Will heed crazysteve's advice and order the progressive springs, while i'm in there, is there anything else that should be replaced or pay special attention to?
Is there a way to test the dust cap or should they also be replaced?

BTW (boats.net) $17.50 each is the cheapest place I found online for Genuine Yamaha fork seals.
And (powersportsuperstore.com) for Progressive springs $61.20 free ship

What method do you recommend for supporting the front frame while on centerstand for fork removal?

[crazy steve]

Is there a way to test the dust cap or should they also be replaced?

As long as they still have a 'friction fit' on the fork tubes (and aren't torn, etc), they'll be fine....

[New2Me]

[QUOTE=

What method do you recommend for supporting the front frame while on centerstand for fork removal?[/QUOTE]

If you dont have a bike/atv lift you could try jacking the bike up from the cross bar in front of the engine then place a jack stand on each side. Hopefully that gives you enough lift. Personally I just bought a lift for $100.

By the way thank you for that link because I was just looking for springs.

[Nubian]

I was wrong on the free shipping

[New2Me]

I just seen that as I was trying to order them. But I was looking at jackets and hand grips to get the $75 min. Both are items I want and they got some good prices.

[motoman]

Just rock it back on the center-stand and block under the filter housing.........simple and painless..........

[bikerphil]

I will be undertaking the task of rebuilding my forks.

Don't be afraid to ask what special tools will be required for this, which are not mentioned in the service manual.

[Nubian]

Don't be afraid to ask what special tools will be required for this, which are not mentioned in the service manual.

huh? are there special item specific tools required?

[bikerphil]

If you have an impact gun and a long reach 8MM allen socket you might get lucky and not need a damper rod holding tool. One can be made from a 2" long 19MM head bolt and 2 nuts...





The seals are interference fit (tight) and can be a bear to get out, one of these automotive seal pullers makes quick work of it...

[Nubian]

If you have an impact gun and a long reach 8MM allen socket you might get lucky and not need a damper rod holding tool. One can be made from a 2" long 19MM head bolt and 2 nuts...





The seals are interference fit (tight) and can be a bear to get out, one of these automotive seal pullers makes quick work of it...

I do have an impact gun.
Would this work? If not i'll just buy one or the set. I do like that seal puller.

[bikerphil]

That allen you have will only work on the bottom of the left fork, the right side one you'll need the long one for. You can make a long 8MM by taking a regular L type allen and cutting the long part off with a die grinder and putting it in an 8MM socket, JAT. Without the seal puller, you'll probably have to collapse the seal somehow without damaging the soft aluminum fork leg. Some people have had luck prying the seal out with a big screwdriver, YMMV.

[Nubian]

That allen you have will only work on the bottom of the left fork, the right side one you'll need the long one for. You can make a long 8MM by taking a regular L type allen and cutting the long part off with a die grinder and putting it in an 8MM socket, JAT. Without the seal puller, you'll probably have to collapse the seal somehow without damaging the soft aluminum fork leg. Some people have had luck prying the seal out with a big screwdriver, YMMV.

Another option I noticed is that a 5/16 fits right into a 8mm socket also.

Expected labor hrs?

[bikerphil]

Couple hours at least, maybe more. You'll also need something to drive the new seals in without damaging them. I use a PVC adapter fitting from Home Depot with the OD ground down a bit. A socket of the correct size would work too.

[New2Me]

I used bikerphils process last night and it worked perfect. In his post he says to get a hex bolt with a 19mm head which is actually a 12mm bolt. I then placed the plastic bolt wrapper over the head of the bolt and pressed into a deep well socket. 2 extensions and a ratchet completed the "tool". With my electric impact on the outer allen bolt it worked perfectly.

[crazy steve]

A standard 3/4" hex nut (1/2" thread) works also...