Old 14th February 2013, 12:12 PM #1
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Forkseal / springs/ bushes replacement

I've seen posts asking how difficult is it to replace your own fork seals. This can vary widely with model, available tools and ability. I took pics of such a job recently so I said I'd stick them up as a guide


first you have to get the fork legs off - top tip - loosen top triple tree hold on leg, then with the bottom tree still tight on the leg, loosen top fork nut, dont remove, just loosen. Its the last time you will have a good grip on the stanchion without resorting to a vice which could damage the fork stanchion.




use a ratchet strap to lift the front with the centre stand




the bottom retaining bolts are the only way to drain the oil on these forks so they have to be removed. Do this while the spring is still under compression (dont remove top for cover) as it will help stop the inner part spinning. If that happens then you will be stripping top cap, removing springs and washers and trying to find a way of locking the inner. pic later



when they are done, remove dust seal

and retaining clip


remove top cap, if they have a load adjuster loosen these fully first as the spring is under compression and may take the chin off you

here is top cap removed, top washer and spacer

remove damper rod


lift out the internals and drain the oil

a few sharp tugs on the stanchion will pull up the seal, if the bush puls through the seal you will have to dig the seal out seperately




the centre part of the above pic is the damper section of the fork and if the bottom bolt spins when yuo try to open it then this is what you will be trying to restrain from the top side, usually a broom handle or a nut welded onto a rod and pushed down through the stanchion from the top (if that makes sense)


The bushes are also being replaced so spring off the bottom bush and remove the old seal and the top bush


the lower legs are being scrapped because there are broken studs for the mudguard and it was easier buy another set


re-assembly time

there was a few large pits at the top of the stanchion between the yokes, I didn't want to oilstone them down because the chrome would be further removed, and I didn't want them catching the seal face on the way down the stanchion. I used a piece of negative to "travel" the seal into place.






the damper section was dropped into place and held with the bottom retaining bolt loosely


then the fork leg and stanchion were assembled and the seal tapped into place with a section of plastic pipe swaged to be a good fit on the outer of the seal, then the retaining clip replaced







here is where I am going to deviate from the norm. I decided to fit gaitors as the seals are being replaced yearly and it's a major pain in the hole. The bike is used daily and parked in a dusty environment. Earache from the site sent over some gaitors that were recommended for the job, but as you can see, they looked stretched and basically shite.



I had had a problem with gaitors on B40 forks and a few covers from PTFE tape got me out of a hole. So worth a try.



fekn bingo, could have been made for the job



bit of black tape





rest in next post

Last edited by nogthebold; 15th February 2013 at 08:09 AM.
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Old 14th February 2013, 12:38 PM #2
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Re: Forkseal / springs/ bushes replacement

cold wet and mouldy place to work....!!are you up the mountains where it always rains ?
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Old 14th February 2013, 01:01 PM #3
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Re: Forkseal / springs/ bushes replacement

Originally Posted by Gellum
cold wet and mouldy place to work....!!are you up the mountains where it always rains ?
twas worse putting them back on, 2am, with a lead lamp and fekn freezing
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Old 14th February 2013, 01:37 PM #4
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Re: Forkseal / springs/ bushes replacement

Originally Posted by nogthebold
twas worse putting them back on, 2am, with a lead lamp and fekn freezing
nice job..lot a rizzlas around
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Old 14th February 2013, 01:51 PM #5
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Re: Forkseal / springs/ bushes replacement

Nice one, Nig. I've got two sets of those to do in the near future
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Old 14th February 2013, 01:55 PM #6
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Re: Forkseal / springs/ bushes replacement

good stuff gonna do mine when im putting in that nice,new rear shock...
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Old 14th February 2013, 02:08 PM #7
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Re: Forkseal / springs/ bushes replacement

what the tip on the fugi film for?
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Old 14th February 2013, 02:16 PM #8
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Re: Forkseal / springs/ bushes replacement

just checking if new springs fit, wont be fitted until oil filled


correct oil amount for each leg



and a rough level guide




when levelling the oil in the forks it's handy to make sure there is no air in the parts were recently out of oil. With the springs out but the oil in place, hold the palm of your hand over to "mouth" of the stanchion to create a vacuum as you pull the stanchion upwards out of the leg. This is a crude but effective way of de-gassing the oil but needs to be done about twenty times
rebuilt legs ready to go back on



halfway


there



re-assembly was at 2am to try and catch "wallys" trip to Midleton.

Would I do it again. No fekn way, too much hassle, easier to take the legs off and give them to someone who wont destroy the place in oil, forget the order of the washers on re-assembly and has some modicom of the art of "dialling in" your suspension.

I still havent got round to setting the sag yet LOL another day

Last edited by nogthebold; 14th February 2013 at 03:17 PM.
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Old 14th February 2013, 02:18 PM #9
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Re: Forkseal / springs/ bushes replacement

Originally Posted by YAMER
what the tip on the fugi film for?
pits at the top of stanchion were sharp edged and I didn't want them cutting or scratching the face of the oil seal.
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Old 14th February 2013, 02:48 PM #10
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Re: Forkseal / springs/ bushes replacement

Nicely done Nog,and timely too,have to do the LM.

Last edited by Fledermaus; 14th February 2013 at 02:50 PM.
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Old 14th February 2013, 05:00 PM #11
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Re: Forkseal / springs/ bushes replacement

I think Kr1ega do fork seal covers, could work out better than those gators, could be worth a look. Good job by the way
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Old 14th February 2013, 05:07 PM #12
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Re: Forkseal / springs/ bushes replacement

Originally Posted by stevieorama
I think Kr1ega do fork seal covers, could work out better than those gators, could be worth a look. Good job by the way
doubt it, gaitors are from an age when bikes were ridden in all weathers and they were there to save the (then a lot more primitive) seals,

as bikes started to get "chromed up" and used a lot less in rough weather the trend was to not fit them for aesthetics



there are old skule, hidden away on this particular bike, but I would be interested to see if the seals last any way longer with them
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Old 14th February 2013, 10:17 PM #13
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Re: Forkseal / springs/ bushes replacement

Good thread, are rizzlas essential??
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Old 15th February 2013, 08:11 AM #14
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Re: Forkseal / springs/ bushes replacement

Originally Posted by StarBoy
nice job..lot a rizzlas around
Originally Posted by Nelly
Good thread, are rizzlas essential??
rollies, the bin should also show a rake of domingo/drum packets - gonna check that now

yep I see tobacco pack and boxes of filters

yer honour

Last edited by nogthebold; 15th February 2013 at 08:12 AM.
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Old 15th February 2013, 10:18 AM #15
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Re: Forkseal / springs/ bushes replacement

Nice work with the negative. i use tape instead.

Here is my forkseal driver. Its an old fork leg cut in half, and the edges smoothed down and covered in tap to prevent any scrapes.

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Old 15th February 2013, 01:48 PM #16
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Re: Forkseal / springs/ bushes replacement

great write up
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Old 15th February 2013, 02:16 PM #17
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Re: Forkseal / springs/ bushes replacement

Originally Posted by jamesk
Nice work with the negative. i use tape instead.

Here is my forkseal driver. Its an old fork leg cut in half, and the edges smoothed down and covered in tap to prevent any scrapes.

Where'd you get that idea

I should have put a patent on that!!
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Old 15th February 2013, 02:31 PM #18
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Re: Forkseal / springs/ bushes replacement

Originally Posted by jamesk

Here is my forkseal driver. Its an old fork leg cut in half, and the edges smoothed down and covered in tap to prevent any scrapes.
I've two spare, nothing a grinder cant fix to make a slide hammer
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Old 30th May 2013, 10:50 AM #19
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Re: Forkseal / springs/ bushes replacement

hi lads semi-related question oil level in an rvf400 fork spring removed??fork fully compressed?damping rod down?is it the inner tube that the level is measured from or the outer tube??it is supposed to be 74mm but from where and with the correct ml of oil im way off 74mm!!
any help greatly appreciated
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Old 18th December 2014, 11:10 AM #20
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Re: Forkseal / springs/ bushes replacement

Originally Posted by kilkenny
hi lads semi-related question oil level in an rvf400 fork spring removed??fork fully compressed?damping rod down?is it the inner tube that the level is measured from or the outer tube??it is supposed to be 74mm but from where and with the correct ml of oil im way off 74mm!!
any help greatly appreciated
Got a master class in this during the week fork oil level is measured with the spring removed, and the best way is with a pipe on a syringe to suck the excess out to the measured / required level.

or bring it down to Mouse1200 during the week and he'll sort it out for ya.
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Old 16th April 2015, 03:53 PM #21
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Re: Forkseal / springs/ bushes replacement

Howdy ,out of curiosity im wondering how you have gotten on with the gators fitted .pros and cons ?
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Old 16th April 2015, 04:21 PM #22
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Re: Forkseal / springs/ bushes replacement

Originally Posted by Jaded
Howdy ,out of curiosity im wondering how you have gotten on with the gators fitted .pros and cons ?
never touched seals since that date (usually done every year) new springs and gaitors did work because bikes mileage per week went from 30 to 400 miles for the last 8 months and not a problem
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Old 16th April 2015, 04:53 PM #23
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Re: Forkseal / springs/ bushes replacement

Impressive ,did you ever slide down the gater and see was there moisture ect ?
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Old 17th April 2015, 01:25 PM #24
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Re: Forkseal / springs/ bushes replacement

Originally Posted by Jaded
Impressive ,did you ever slide down the gater and see was there moisture ect ?
yep, checked every few weeks or so. No indication of any problems and none of the telltale oil weep at the top of the seal. One of the plastic inserts I used broke up and haven't gotten around to changing because no ill effect. Gator still works in keeping area clean
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Old 17th April 2015, 01:36 PM #25
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Re: Forkseal / springs/ bushes replacement

Result ,thanks for the info
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Old 5th October 2015, 06:26 PM #26
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Re: Forkseal / springs/ bushes replacement

Good pics and write-up

I put the seal on the fork tube from the other end before putting the bush on.
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Old 21st December 2015, 12:19 PM #27
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Re: Forkseal / springs/ bushes replacement

nice advice there, going to bo mine in the new year just the fork seals and the rusty dust seals.
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Old 21st December 2015, 12:32 PM #28
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Re: Forkseal / springs/ bushes replacement

Originally Posted by nogthebold
doubt it, gaitors are from an age when bikes were ridden in all weathers and they were there to save the (then a lot more primitive) seals,

as bikes started to get "chromed up" and used a lot less in rough weather the trend was to not fit them for aesthetics



there are old skule, hidden away on this particular bike, but I would be interested to see if the seals last any way longer with them
its the chrome that made the biggest difference, most of the older yokes had no chrome on the tubes thus the weather would start the rust pretty quickly .the gaiters were a bit of protection .
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Old 21st December 2015, 01:19 PM #29
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Re: Forkseal / springs/ bushes replacement

Originally Posted by chopper
its the chrome that made the biggest difference, most of the older yokes had no chrome on the tubes thus the weather would start the rust pretty quickly .the gaiters were a bit of protection .
is it a balls of a job to do it on a bandit 12, any tips appreciated
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Old 21st December 2015, 03:42 PM #30
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Re: Forkseal / springs/ bushes replacement

Originally Posted by Michael McDowell Senior Counsel
is it a balls of a job to do it on a bandit 12, any tips appreciated
check out this video from Delboys garage.
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