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Replace/renew fork seals, post pics (Read 1277 times)
Gyrobob
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Replace/renew fork seals, post pics
03/22/11 at 05:31:43
 
I searched for some posts on how to redo the fork seals, but couldn't find any.  I would have thought with the zillions of posts here, that someone would have documented that procedure.

Since our double CS-1 effort is underway nicely (http://s258.photobucket.com/albums/hh253/Gyrobob_theOriginal/Motorcycle/RYCA%...), we are thinking that now might be a good time to redo the seals, since all four forks are out on on the bench.

None of the forks were leaking badly, but all of them had a least a little film of oil on the stanchions.

On a related subject, where's the best place to get the seals, and where can we get the gaiters shown in other posts here?

On an unrelated subject, how do we attach pics to posts?  I keep getting an error message when I try to attach small (~150kb) .jpg files.

Thanks for any info,

Bob
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MotoBuddha
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Re: Replace/renew fork seals, post pics
Reply #1 - 03/22/11 at 06:18:50
 
I replaced my seals. Whether I did a good job of it remains to be seen.



You get the old ones out by pulling off the wipers (3 in the drawing above) and removing the retaining clip (4), then yank the fork out of the slider. The seal (5) will come out with the fork.

A bronze bushing (7) is seated in a recess on the bottom of the fork. I didn't change that. Ignore this. It's wrong. The bushing isn't in the recess. Sorry for the mistake.

There's a small aluminum cap (11) that fits in a recess in the bottom of the fork. It might come out with the fork tube, then fall on the floor and roll to an inconvenient place, or it might stay at the bottom of the slider. Just be sure it's in the bottom of the fork tube, open end in, small hole out, when you reassemble the fork. A dab of grease on the cap will keep it from falling out while you put things back together.

Slide the old seal off the fork, slide the new one on.

Now this is where it gets tricky. If I were the kind of person who changed fork seals for a living, I'd have a tool that slides down the fork and lets me ram the seal back into place. Or I might have kludged up a piece of pipe or something. Instead, I happend to have ordered an extra pair of washers that go under the seal (6). So I slid the old ones on top of the new seal and used a punch and hammer to tap the seal into place, working bit by bit around the fork, until all the seal was below the groove for the clip (4).

Getting the clip back in requires some coordination and patience. Make sure to push it well into the groove.

Then push the wiper back into place (I got new ones) and you're done.

I got the seals and a crapload of other parts from cheapcycleparts.com. Maybe I should have gotten a fork seal tool from them while I was at it.  Grin
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« Last Edit: 03/25/11 at 07:01:12 by MotoBuddha »  

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Gyrobob
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Re: Replace/renew fork seals, post pics
Reply #2 - 03/23/11 at 10:46:43
 
Thanks huge.  this is exactly what I was looking for!

Also, when will we be able to attach pics to posts?
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verslagen1
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Re: Replace/renew fork seals, post pics
Reply #3 - 03/23/11 at 10:56:43
 
Depending on what your referring too...
Never again
or right now.

Can you upload pictures to SS? no, never again.  pay no attention to the instructions while posting.  If I could change them I would.

But you can link pictures from other file sharing sites like bikepics.
just paste the web addy in your post, highlight it, then select the insert picture icon  
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Serowbot
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Re: Replace/renew fork seals, post pics
Reply #4 - 03/23/11 at 11:00:06
 
Fork boots,... MSR Daystar "series 58", for about $15.00 at aftermarket stores and internet...

Posting pics,...
Read here...
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1240899665
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MotoBuddha
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Re: Replace/renew fork seals, post pics
Reply #5 - 03/23/11 at 12:05:41
 
verslagen1 wrote on 03/23/11 at 10:56:43:
Depending on what your referring too...
Never again
or right now.

Can you upload pictures to SS? no, never again.  pay no attention to the instructions while posting.  If I could change them I would.

But you can link pictures from other file sharing sites like bikepics.
just paste the web addy in your post, highlight it, then select the insert picture icon   http://suzukisavage.com/yabb2.2/Templates/Forum/default/img.gif


Photobucket, and maybe some other photo hosting sites, give you and IMG code to copy and paste into your post, meaning no other steps necessary to post them here



When you paste it, you'll just see the code, like this:



But you can see the picture in the preview and in the actual post.

Using a photo hosting service isn't the most convenient way to deal with this, because you need to upload the pictures first, but that's life.

Smiley
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Gyrobob
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Re: Replace/renew fork seals, post pics
Reply #6 - 03/24/11 at 07:37:44
 
Motobuddha, I will be ordering 4 each of parts 3 (dust seal), 5 (fork seal), and 6 (washer).  Why did you order part 6 (washer)?

I just tried to take apart one fork.  The dust seal came off easily, as did the stopper ring (4),.... but even with some pretty hard yanking, I can't get the fork seal to budge.   Angry  

Any techniques for this?
Heat?  
oil soaking?  
dissolve the seal?  
soften the seal with auto trans seal sweller?  
continuous pull on the tube for hours until the seal lets go?  
go find 320 lb BillyBob?


I can see the value of a fork seal installation tool.  Something with half a mm less OD than the seal but with an ID (38mm) that matches the upper tube's OD.  I'll probably have to gently and very patiently go around the seal with a soft punch, tapping it in .001" at a time.

Thanks much,

Bob
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Re: Replace/renew fork seals, post pics
Reply #7 - 03/24/11 at 08:03:06
 
Quote:
You get the old ones out by pulling off the wipers (3 in the drawing above) and removing the retaining clip (4), then yank the fork out of the slider. The seal (5) will come out with the fork.


Yank, billybob style till it come out... yeah    Huh
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MotoBuddha
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Re: Replace/renew fork seals, post pics
Reply #8 - 03/24/11 at 08:25:23
 
Gyrobob wrote on 03/24/11 at 07:37:44:
Why did you order part 6 (washer)?


By accident. But it came in handy.
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MotoBuddha
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Re: Replace/renew fork seals, post pics
Reply #9 - 03/24/11 at 08:44:22
 
Gyrobob wrote on 03/24/11 at 07:37:44:
I can see the value of a fork seal installation tool.


http://www.rswracing.com/sealdrivers.htm

http://www.moto-pro.com/ProductPage.asp?strMPSID=FSDR37

http://www.google.com/products/catalog?q=fork+seal+tool,+38mm&hl=en&lr=&safe=...

Like I said, I might get a tool if I were doing this a lot.
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Re: Replace/renew fork seals, post pics
Reply #10 - 03/25/11 at 06:16:44
 
When the stanchion finally pulled out of the lower fork tube, the seal came out fine, as did the bushing.  

In my quest to improvise a tool I tried to get the bushing back inside the recess in the lower tube.  It doesn't want to slide back in there very easily.  Is there a simple way to get it back in the recess?  I hate to force things like this.
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Re: Replace/renew fork seals, post pics
Reply #11 - 03/25/11 at 06:28:01
 
I misspoke about the bushing. I was thinking about the piece at the very end of the tube. The bushing slides on and off. Sorry for the confusion. I was working from my faulty memory. Here's the picture from the manual. The bushing is A.

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Gyrobob
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Re: Replace/renew fork seals, post pics
Reply #12 - 03/25/11 at 09:42:26
 
Yes,...  Mine looks just like that.

Now, what is the smooth and easy way to get the bushing back into the recess in the lower tube?  When I try to reassemble everything, it all starts sliding together nicely up until the bushing hits the lower tube and won't go in far enough to allow the seal to seat.
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Gyrobob
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Re: Replace/renew fork seals, post pics
Reply #13 - 03/28/11 at 09:15:48
 
I found a $3.00 solution for a fork seal installation tool.
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MotoBuddha
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Re: Replace/renew fork seals, post pics
Reply #14 - 03/28/11 at 12:09:31
 
And..........?

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