Fork Seal replacement

[Deleted]

Hi Guys,

Have never done this but need to on my brothers bike, any tips hints etc?

Mark

[Deleted]

Hi Mark,

I've done a few.
Q1 is it USD forks or RWU forks?

1) Make sure you have a clear uncluttered work area.
2) Undo nuts/screws/caps VERY carefully and slowly, the springs offer quite a bit of force.
3) Be methodical, make a note of where everything goes.
4) Strip down the forks as LITTLE as possible.
5) Be very careful removing the old seal. DON'T scratch the 'bearing' surface. IE Don't use a screwdriver to lever out the old seal.
6) keep the new seal square when you PRESS the seal in. Light taps should be OK.
7) Make sure you put the seal in the right way up.
Most important.......
DON'T loose your temper and through bits of fork around the garage!

[Deleted]

I mean 'throw'!!!!

[Deleted]

Cheers Jezz,

They are zxr400 USD forks, how do i get the stanchions out from the forks, I have taken the springs out before but wanted to know how to get too the seal and to replace it??

Thx

Mark

[Deleted]

Hi Mark,

The forks will have to come out of the yokes completely.
one suggestion to make life easier - although you have to be very careful...
To get the slider out of the stanchion there is a bolt in the bottom of the fork leg (hidden by the axle when on the bike) loosen this very slightly with the forks on the bike - other wise its a nightmare trying to stop the stanchion spinning round while you undo this bolt. This bolt is what effectively what holds the two halves of the fork together. Bear in mind oil will drain through this bolt hole. When you then slide the fork leg from the stanchion you will clearly see the seal under the dust cap in the top lip of the stanchion.
The spring etc must come out of the top of the fork before seperating the fork.

Good luck!

[Deleted]

Cheers mate, will give it a go!

mark