Changing Fork Seals on a Special

[bikerphil]

Yep, a trick I use sometimes is to take a piece of thin plastic soda bottle cut to the proper size or a film negative and wrap it around that lower stantion bushing when sliding it past the seal, then pull the plastic out when it's past. No chance of it getting sliced that way.

[DGXSER]

Yep, a trick I use sometimes is to take a piece of thin plastic soda bottle cut to the proper size or a film negative and wrap it around that lower stantion bushing when sliding it past the seal, then pull the plastic out when it's past. No chance of it getting sliced that way.

First off, for the inquiring minds, yes, the seal was torn to hades in a hand basket along in a couple spots. All I can figure is exactly as Phil suggested, the upper tube tore the crap out of it going in. I used Phil's method quoted here on the installation this go around. No tears, and no leaks. Put about twenty miles on yesterday after adding air with the replaced replacement seal. No leaks as of today.

[jjz28]

When I took my seals out, there was a spacer like washer under the seal and then another washer on top of it. There was no washer under the c-clip. Did the PO get this mixed up? is there supposed to be a washer under the c-clip and then the spacer/washer under the seal? I bent the spacer washer a little getting it out. I didn't realize it was under there. If anyone knows, please let me know as I am doing this right now. thanks.

[GLoweVA]

When I took my seals out, there was a spacer like washer under the seal and then another washer on top of it. There was no washer under the c-clip. Did the PO get this mixed up? is there supposed to be a washer under the c-clip and then the spacer/washer under the seal? I bent the spacer washer a little getting it out. I didn't realize it was under there. If anyone knows, please let me know as I am doing this right now. thanks.

Jeff, I haven't taken my forks apart ever, so I'm no expert here, but the drawing in the 3 manuals I've got only shows pics for the standard forks and it goes: snap ring, oil seal washer, then oil seal.
On a different note, the parts fiche shows the 79SF as having: oil seal stopper ring(snap ring?), oil seal, seal spacer.
Reading DG's thread here, he had the snap ring, washer on top of seal, the oil seal and a washer/collar under the seal:

Now that you have the old seal out, there is another washer/collar under the seal.

So it's highly possible that the PO had put the oil seal washer in the wrong place and that might have been why the seal failed. JAT.
I could suggest taking the other fork apart and seeing how that one went together. Just try not to get the parts mixed between the two.

[jjz28]

Thanks George, I think I have it right. I am only going to do the one seal right now cause the other one don't leak. I probably should do them both but oh well. thanks.

[jjz28]

Are the seals supposed to go in pretty hard? I am scared to death to tear it up. I have an extra if needed. I don't have a socket the right size so I am trying to find something to use that wont mess the seal up. Does it go flush with the spacer below?

[GLoweVA]

Are the seals supposed to go in pretty hard? I am scared to death to tear it up. I have an extra if needed. I don't have a socket the right size so I am trying to find something to use that wont mess the seal up. Does it go flush with the spacer below?

I bought a piece of PVC pipe to drive the seal in as suggested in the tech thread, but I think that's for the standard fork size. I ASSUME (you know what that means) that the special forks a little smaller in diameter.

[jjz28]

I got it in, hopefully I didn't bugger that lip putting the lower tube in. I used a water bottle to get over that sharp edge. Time to get the fluid in and put that crazy cap back on.

[DGXSER]

Jeff, yes, the collar goes flat side down first, then the seal goes in, then the washer on the seal, and finally the clip.

A method I used on my GSX forks to install the seal was to take a piece of 1-1/4" PVC pipe about 12" long, cut a slit down the middle of it. Put the tube in the slider, put the collar down, slide the seal over the tube, then the washer over the seal. Now slide the PVC over the fork tube, it will be a tight fit. Pull the tube up and hold it up while you Slide the PVC down to about 6" above the seal sitting in place, ready to be pushed in. Now you can use the tube/PVC pipe like a slide hammer to drive it in place. Once the seal and washer are down enough for the clip to go in the slot, slide the PVC back up off the tube.

Best thing I ever did for putting the cap back on was to take a piece of 1 X 3 oak and cut a notch in it the small end the same size as the air valve pocket on top of the cap. Put the wood over the cap and use it like a wrench to both push down and twist the cap.

[jjz28]

Oh, I don't think I put it flat side down cause the fork looked like it was made to go the other way. I hope I didn't screw this up. So, far, by hand its not leaking, guess i'll find out when I take it for a ride. Thanks guys.

[DGXSER]

I doubt it will make any real difference Jeff. You should be good to go.

Worse case, they leak, and you get to repeat the effort. At least you already have a spare set!

[jjz28]

Haha, yeah Don, I guess your right there. Hey by the way, Great right up! I know it really helped me and it wasn't bad at all. The bolt came right out the bottom and it only took maybe 45 seconds to get the cap on with visegrips as a handle.

[jjz28]

Yeehaw no leaks and I got my shield on and went for a ride.

[DGXSER]

Very nice, good work Jeff!

[rdmcguy]

fork seals

It must be the day to replace fork seals.
I have had a good amount of luck with a different technique.
I loosen the allen bolts before I take anything off.also loosen fork caps,
Elevate the front end,remove wheel brakes etc.
leave the fork tubes in the triples,pull the lowers off,
clean, rinse,install new seals, slide them back on,
reinstall wheel, brakes etc. fill with oil and go.
I also have on occasion removed valve stem from fork caps and used large syringe to fill legs.
From time to time the allen bolts have been difficult to remove,
compressing the forks seem to help.
when all else fails jam a broom handle into fork leg to prevent damper rod from spinning,good luck!