Fork Seals, the bodgers way.. A how to :D

[hmmmnz]

well after a leaky fork thats been bugging me for a while, i decided i'd do it
so he we go, bear in mind, that this isn't how the manual tells you to do it, but who the hell has a "kawazaki/honda/susuki/yamaha fork tool" ?? i certainly don't.

step 1.

put the bike on the center stand/jack ect, or make do with what you have about no harm in being creative

https://i58.photobucket.com/albums/g257/hmmmnz/DSCF0619Small.jpg

step 2.

remove the brake calipers from the forks

https://i58.photobucket.com/albums/g257/hmmmnz/DSCF0620Small.jpg

step 3.

remove the wheel and the mudguard (if you have one )
remember where the spacers go

https://i58.photobucket.com/albums/g257/hmmmnz/DSCF0621Small.jpg

step 4.

undo the bolts ect that hold the forks in the yokes, (you can unbolt the top of the fork at this stage) i prefer to slide the forks down and unscrew it using the bottom for clamp to hold the fork in place

https://i58.photobucket.com/albums/g257/hmmmnz/DSCF0622Small.jpg

step 5.

remove the forks completely from the bike, drain them into a bucket,
then, grab a flat blade screwdriver and ply off the dust seal.

https://i58.photobucket.com/albums/g257/hmmmnz/DSCF0623Small.jpg
https://i58.photobucket.com/albums/g257/hmmmnz/DSCF0624Small.jpg

step 6.

remove the little metal oil seal holding clip (again with flat bladed driver)

https://i58.photobucket.com/albums/g257/hmmmnz/DSCF0625Small.jpg

step 7.

the tricky bit this is where the real bodging begins.
get a self tapping wood screw, yep you heard right
and a small hammer and tap the screw into the center of the oil seal, trying to penetrate the metal that the seal is made of under the rubber. when you have pierced the metal then with som weight screw in the screw just enough that it bites
try not to scratch your fork!!! (its made of tough stuff, but still be careful)
https://i58.photobucket.com/albums/g257/hmmmnz/DSCF0626Small.jpg

step 8.

pull the seal out with a set of pliers, and slide off the forks
https://i58.photobucket.com/albums/g257/hmmmnz/DSCF0627Small.jpg
and here are 2 i prepared earlier :d
https://i58.photobucket.com/albums/g257/hmmmnz/DSCF0628Small.jpg

step 9.
put the new seals in, replace the spring/seal holder, dust seal,

step 10.

slide the fork into place,

step 11.

put the wheel, brakes ect back on.

step 12.

fill with the recomended amount of oil

https://i58.photobucket.com/albums/g257/hmmmnz/DSCF0629Small.jpg

step 13.

screw the top back on the forks,
you are done!!

one perfectly functioning non diving rat fighter
https://i58.photobucket.com/albums/g257/hmmmnz/DSCF0630Small.jpg

and i bid you adieu
____________________
the humans are dead
I kick arse for the lord
Wiring Diagrams BIDNIP it bitches

[Evo]

Good Guide There. Kudo's to you
____________________
Bikes owned
1989 VFR 400 RR NC30

[teabag]

........and to get the new seal to go in straight get a length of 40mm waste pipe from your local DIY shop, slide it over the fork leg ont the seal then bash it with a hammer. Pressure is applied evenly to the seal and down it goes!! Need a bigger pipe for fat forks, of course.
____________________
NS125R = 2 years > GSX600F = 7 years > XR125L = 3.5 years > SV650S........and a Citroen Synergie HDI for the kids.

[hmmmnz]

i just use a screw driver and gently press it down, never had any bother but a pipe is better
____________________
the humans are dead
I kick arse for the lord
Wiring Diagrams BIDNIP it bitches

[Ichy]

Then three weeks later, when it starts leaking again, you can do it properly and changes the bushes at the same time


Sorry mate, nice bodge, but I can't imagine everyone who decides to give it a go would be as careful as you with the woodscrew.

For the sake of one extra bolt a special tool can be made out of a bolt and a metal bar.

[hmmmnz]

[MementoMori]

Good old kiwi ingenuity!
____________________
The tiger who came for a pint

[hmmmnz]

yep gotta make do with what you got
____________________
the humans are dead
I kick arse for the lord
Wiring Diagrams BIDNIP it bitches

[iloveriding]

I think we should rename HMMMNZ to the GURU, keep the usefull info comming mate, Tony
____________________
Ride Safe, Stay Safe, Be Safe, Be Seen And See All Other Idiots on the road

[ZRX61]

[Vincent]

Also best to rub a bit of fork oil on the inside of the seal and make sure you bleed the forks too