Replace fork seals

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Replace fork seals

Postby amstel78 » 10:03 am Jul 17 2012

I need to replace the fork seals on my bike and a local shop has quoted me $90 plus parts to do the job. I already have the seals and normally wouldn't mind attempting this job on my own but I don't have the specialized tools specified by the manual. Does the quoted price of $90 sound reasonable?

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Re: Replace fork seals

Postby Julien D » 11:08 am Jul 17 2012

I think it runs about $75 plus parts around here. Not terrible. The specialized tools can be fabricated pretty easily, if you decide to tackle it yourself.
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Replace fork seals

Postby scheckaet » 11:26 am Jul 17 2012

I don't think the tool is absolutely necessary, I think I used super long flat screw driver to hold the piece is place (it's bee awhile though...)
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Replace fork seals

Postby Jason » 06:59 pm Jul 17 2012

Where is NEPA?? I will do it for Pizza Hut and Dr. Pepper. :grin:
Thank you, Julien D for all your hard work!

PLEASE! Do not "dip" PWK Keihin carbs in Berryman's to clean them! It will damage the internal o-ring (jet block gasket).
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Replace fork seals

Postby amstel78 » 09:14 pm Jul 17 2012

Jason wrote:Where is NEPA?? I will do it for Pizza Hut and Dr. Pepper. :grin:


LOL, I wish I could take you up on that offer. I'd even throw in a case of your favorite beer should you so desire. NEPA is short for North East Pennsylvania. You're a bit too far for a weekend road trip!
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Replace fork seals

Postby rbates9 » 09:44 pm Jul 17 2012

Im in upstate NY and would offer the same service - the Dr Pepper and + the Beer. :grin:
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Replace fork seals

Postby amstel78 » 09:58 pm Jul 17 2012

rbates9 wrote:Im in upstate NY and would offer the same service - the Dr Pepper and + the Beer. :grin:


Where in NY are you exactly?
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Replace fork seals

Postby rbates9 » 10:31 pm Jul 17 2012

amstel78 wrote:
rbates9 wrote:Im in upstate NY and would offer the same service - the Dr Pepper and + the Beer. :grin:


Where in NY are you exactly?


About an hour north east of Albany. 5 miles from Vermont.
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Postby Jason » 08:52 am Jul 18 2012

Oh well. Good luck on the rebuild. I am off to cook and pour my own drink. :grin:
Thank you, Julien D for all your hard work!

PLEASE! Do not "dip" PWK Keihin carbs in Berryman's to clean them! It will damage the internal o-ring (jet block gasket).
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Replace fork seals

Postby amstel78 » 10:06 am Jul 19 2012

I've found a few 43mm fork drivers for under 40 bucks online, but am hesitant to spend 40 dollars on something that'll get used rarely. Any other suggestions as to what can be used to pound the fork seals back in without damaging them?
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Postby Dekon » 10:17 am Jul 19 2012

On my Beta, I used a piece of PVC pipe. I put the new seal on the fork, put the old seal on top of the new seal so I would not damage it and then used a piece of PVC pipe to drive it in. But, the Beta is a trials bike and the forks are of a much smaller diameter. Maybe you could find a piece of PVC that has the right diameter.
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Postby scheckaet » 11:35 am Jul 19 2012

pvc pipe and old seal worked for me.
02 KX 200 hybrid: RB head and carb :prayer:
DRZ 400 SM :supz:

bike build: viewtopic.php?f=111&t=8245&hilit=bike+stable
bike profile viewtopic.php?p=30709#30709

newb info: viewtopic.php?f=77&t=12457#p117919
jetting guide: viewtopic.php?f=105&t=1156
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Replace fork seals

Postby amstel78 » 12:20 pm Jul 19 2012

Another question: the service manual states the fork takes 618ml or 20 oz of oil. Is that per damper or both?
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Postby amstel78 » 12:38 pm Jul 19 2012

OK, one more question. The manual states that I have to remove the cylinder valve assembly when disassembling the forks. Is that absolutely necessary? That requires two special tools which I don't have. Can't I just remove the top bolt, remove the spring seat and spring, drain the oil, then proceed to separate the inner tube from the outer tube by first removing the dust cover then the snap ring??? :hmm:
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Re: Replace fork seals

Postby amstel78 » 06:06 pm Jul 26 2012

I take it from the lack of responses that the manual's correct in that I'll have to remove the valve assembly to get the damper apart? Sorry for so many questions, but sometimes the service manual isn't very clear.
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Postby Jason » 10:05 pm Jul 26 2012

Yes, you have to take the cartridges out before separating the tubes. Buy a 14mm hex socket and FRP Offroad cartridge tool.

Pour boiling water on the seal area before separating the tubes. You will WHACK the bushings to death (if they are not already shot), otherwise.
Thank you, Julien D for all your hard work!

PLEASE! Do not "dip" PWK Keihin carbs in Berryman's to clean them! It will damage the internal o-ring (jet block gasket).
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