Changing Fork Seals on a Special

[DGXSER]

RD,

I like alot of your suggestions. I would say that is a good idea to loosen that bottom hex bolt before removing the cap all the way, just loosen the cap before you pull the fork out of the trees.

I am inclined to suggest that if you need to replace the seals in the forks, you should also clean the forks, all of the parts. Leaving the tubes in the trees, you can't get most of the parts out of the tubes and therefore you can't clean the tubes properly. It is really pretty dang easy to get the forks out of the trees once you have the wheel and fender off anyway. JMHO.

[DenyP]

Great Thread! I will be doing my forks in the next couple of days - the extra tips here should be helpful.

Deny

[skids]

Before I put the spring in, I screw the cap in a turn and back it out to see what "oclock" position the threads begin. It makes it sooooo much easier if you know where you're at when you're struggling compressing the spring. This is particularly helpful on these Special fork caps which have course threads. You can also make a special tool for starting the caps ↓

2X2

I LIKE that device. Excellent idea!

[crazy steve]

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.

Same size PVC will work for both.....

Look here.... http://www.xs11.com/forum/showthread.php?t=37399

[Far Canal]

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.

Yes indeed it must be the time to change those seals.
Had mine (1979SF) apart today and was concerned to find in one fork slider I had clip (a wire type one,that you pry out with screwdriver) then the seal(no washer) and under that FOUR washers!. Other fork slider had wire clip then seal then 2 fatter washers!
Thinking previous owner really got it wrong here.
Unfortunately these 1979 SF models never got released here in Australia and the Yamaha shop I went to did not have the suitable exploded view drawing.
The part I think I am most in need of is that spacer/washer that sits under the seal. Going from previous posts it looks like a washer with a slightly turned up outside diameter.
Do any of you good folk over there in the U.S know if this is a part that you can still get?

[bikerphil]

That piece under the seal is made of soft metal and is usually destroyed when the factory installed seal is removed. Chances are you won't be able to find one in good condition anywhere. It is fine to use washers either above or below the seal to achieve the proper thickness for the snap ring to seat. I myself like to use a homemade PVC pipe spacer on top of the seal directly under the snap ring. Good luck with your rebuild!

[Far Canal]

That piece under the seal is made of soft metal and is usually destroyed when the factory installed seal is removed. Chances are you won't be able to find one in good condition anywhere. It is fine to use washers either above or below the seal to achieve the proper thickness for the snap ring to seat. I myself like to use a homemade PVC pipe spacer on top of the seal directly under the snap ring. Good luck with your rebuild!

Thanks Phil. So it seems what your saying about the washers above and below the seal is that they are there to pretty much take up the space thats left over when the fork seal is in place? (for instance I have got 15mm from bottom of snap ring to bottom of seal slot and the seal is 11mm thick, so there is still 4mm of empty space)
Makes one wonder why they didn't just machine out the fork seal slot to the right depth in the first place.
Anyway this site sure is a wealth of good advice.

[bikerphil]

Now that I re-read your previous post, yes I am familiar with that tapered washer that sits below the seal. If you don't have it, don't worry about it, it isn't absolutely necessary. You can use whatever washers you have available to take up the extra space. In the original factory assembly there was a soft metal spacer of the correct size under the seal above the lowest tapered washer. Anyway, the main thing is to fill up the extra gap so the seal sits nice and straight and the snap ring sits in nicely.

Here is what Yamaha shows as the spacers...

http://www.benefiscal.co.uk/partinfo...H3-23146-00-00