I am having trouble replacing my fork seals. Can somebody please help me solve my oil leak problem. Step by step information would be nice.
Heya, i could do with some of the same info.. what do you mean by leaking? is there oil on the fork from moving up and down or is it leaking from somewhere else on the forks?
the FZR english version of the 400 dave posted gives good step by step instructions easy enough for me to try n give it a go this weekend, thou my question being to anyone who has replaced the seals on a FZR is: Is a long extention bit on a socket able to replace the Damper Rod Holder and T-Handle? Cheers for any help Theres also a posting on youtube on how to replace a fork seal but all seems up side down to me <!-- s:-? --><img src="{SMILIES_PATH}/icon_Eyecrazy.gif" alt=":-?" title="Eye Crazy" /><!-- s:-? -->
I did change a fork seal on my 2KR but that was 2 years ago so you will have to take anything I write with a grain of salt. You won't have to do all this hopefully. This is a complete disassembly procedure to allow bush replacement. Just do the bits you need to get the seal out. I reckon you need to only do steps 1, 4, 6, 7, 9 to do the seal replacement but it's a good thing to change the fork oil as you go. 1) I lifted the front by the neck off the ground with a chain block from an overhead beam. Remove the front wheel 2) Pull off the rubber cap at the top of the fork. Press down the internal metal cap at the top of the forktube and remove the circlip with a sharp pointed knife or a small screwdriver. The cap may need a tap with an appropriate size socket and hammer to loosen if its seized a bit. . WARNING, once the circlip is removed, the cap will come out quickly because the spring is pushing it. I think with 3LN forks, the cap screws off 3) The spring should be able to be removed from the top. 4) Undo the triple clamp bolts that hold the fork tube and the clip-on handlebar and then remove the tube from the clamps. 5) Drain the oil out 6) This bit is a bit vague for me but I think the next step is to remove the allen head bolt from the bottom of the fork and I put a long bit of 10 or 12mm aluminium tube down the inside from the top of the fork to hold the nut while it was being undone. 7) I think after that I had to remove the top fork seal by piercing or levering it out of the lower fork housing. Mine was very tight and in the end I heated the aluminium fork with the oxy to loosen up the area. Take care not to overheat aluminium 8) Hold the lower fork in a vice and remove the inner tube. This may be hard to get out and require a lot of force. I know mine did 9) Put your new seal in and re-assemble reverse procedure There are bushes inside the fork that do wear and can be replaced
