Changing fork seals without fork removal from bike??

[bikerphil]

The Special damping rod is less likely to spin in place and it doesn't have acceptance for the bolt (holding tool) like the Standard does. If need be, a broomstick handle can be used as a tool to keep it from spinning.

[sparkfly88]

So I checked the preload screws, both were all the way out already ( pretty fascinating how they drop down as you screw them in, one is frozen though. )

I loosened the top nuts, removed the calipers, and fender, removed the front blinkers looking for the tension bolts, which those ended up being them.

Then the top.

Expected em to fall out, of course not!

Little persuasion from a rubber mallet and some twisting and they came out.


One, seems like the fluid was changed at some point, the oil conditions and levels were VERY different.

One had a large quantity of black oil, which I've never smelt before ( gotta be fork fluid ) it took 4 or 5 pumps to empty the oil out.

the other leaked out some clear fluid ( maybe water ) then two pumps and it was empty, more of a brown fluid than a black like the other one. In the photo its the RIGHT.


popped the boots off to see the seals.

And thats where I'm at as of right now!

[bikerphil]

Do one at a time so parts don't get mixed up between the two, or keep the parts separated. Brake cleaner works well to clean the parts off when apart.
Remember, cleanliness of the internals is very important.

[sparkfly88]

Well, while I was out getting tools, nature decided to say HEY SCREW YOU!


All my tools are waterlogged, and the two little screws for the bottom of the shocks are MIA

[sparkfly88]

HUZZAH !!!

I found em!

[GLoweVA]

Well, while I was out getting tools, nature decided to say HEY SCREW YOU!


All my tools are waterlogged, and the two little screws for the bottom of the shocks are MIA

Since when doesn't it rain in FLA?!
You can almost set your clock to the afternoon storms.

Like the pics, it's always nice to see pic, so others have an idea of what theirs might look like when they take stuff apart.

[sparkfly88]

Thanks! I'll be taking more today when I take Em all apart.

The one that didn't have much fluid in it is oozing thick funk almost like peanut butter.

Can't wait to see that gnarly stuff.

[sparkfly88]

Attempt number one is a FAILURE.


I read about a way to just use the springs pressure to hold everything in place...So, I balanced on the fork strut like a pogo stick, and gave the 8mm impact a little juice.

It broke loose,and then spun around inside the tube, on both.
Don't worry, I didnt let the insides spin around to ruin the inside rubber.

The moment I felt the inside slip, I let off.

I'm sore all over from the awkwardness of balancing on a strut


Step two was to take off the top nut, and peer inside to see where this special 19mm double bolt tool goes..

I couldnt see anything down there with a flash light that makes any sense to me.

[bikerphil]

see where this special 19mm double bolt tool goes

Here's the seal puller.... ↓

[sparkfly88]

So the nut tool connects to the part that spins, and you hold the doublenut side or w/e with a socket and extension?

idk why I can't wrap my mind around this deal.

[DGXSER]

Yes, you will want to remove the spring first, then you put one of the double nut ends down the tube into the damper end, which has a hex head shaped opening in it. Now you use your socket with extensions as needed, to hold the damper from turning as you break the hex screw loose at the bottom of the fork, keep holding the damper rod with this setup till you get the bolt out.

The setup Phil showed only has one nut on the end that goes into the damper rod, his must be held by thread lock or some welding tacks. But a double nut on that end will work just as well. His threaded rod is a little shorter than the 18" mentioned, he must have a longer extension.

Hope that helps some.

[sparkfly88]

I bet I couldnt see the hex opening because there is oil or something on it.


Okay, So I need 19MM headed nuts.

I'll most likely just weld the nuts on the rod.

[motoman]

Guess you realize there is a wide external snap ring on top of seals?

[sparkfly88]

Guess you realize there is a wide external snap ring on top of seals?

Yeah already got those off.

[bikerphil]

The setup Phil showed only has one nut on the end that goes into the damper rod, his must be held by thread lock or some welding tacks. .

Don, in the end of the damper rod is the head of the bolt, the 2 nuts are tightened together and with threadlock, so a 19MM deep socket and extension fit on there so it can be slid into the fork tube easily (fork lying out across the bench). The tool works great and can be stored in a small drawer until next use.