How to change fork seal

[DESE]

So I decided to do a small write up on fork seals since I couldn't find much info on them.... I just did this one today (04 gsxr) again I had to practice on a gsxr before messing with the 6, but the fork seals are the same concept...

So first thing I did is buy this video download, you also get a nice dvd in the mail, it will help a ton for $4.99.... (scroll down to basic fork service) http://www.onthethrottle.com/edownloads/

Then buy this handy dandy fork spring compressor for $36.95, or buy the whole kit $89.95 so the job will be super easy

http://www.traxxion.com/racingsportb...vicetools.aspx

So first off remove the front fairings and headlight....


Then loosen triple tree bolts, clip on bolts, brake caliper, remove front tire, then put the bike on rear stand, I used a regular jack to lift up from the headers just enough to slide the down and out...


fork out...


check preload, rebound, and bottom screw( forgot name) then loosen cap...


Drain oil then Install clip using spring compressor to access the jam nut...


Remove insides in nice neat and orderly fashion...



Remove dust cover...


Remove clip...


remove seal...


Clean very good, then use old seal to tap in the new seal so you don't damage it ( very carefully) ...

[DESE]

now reassemble....


Pour in oil and bleed using the bleeding tool that comes in the kit...


Reinstall the spring...


Then put the washer and spring compressor back on...


Install washer in reverse order then cap back on...



And after you reset your preloads, and rebound your good to go...


Reinstall the tube, tighten up triple bolts.... and your good to go!



Job took an hour total, this was wayyyy easier then I though, The R6 fork is just a tad different and I will be doing mine next weekend so I will post details, the main difference is our tube doesn't come off so you need a pvc pipe to install the fork seal but same concept... I paid $250 for my last fork seal change and my cousin was quoted $400 at the dealership... he paid $20 for his seal, mine was $9.99... Total we paid $140.00 for all tools and seals, saved $510.00!!! Well worth it if you ask me...

[DESE]

Ok so here are a few pics for those of you changing the R6 fork, I did this last week but didn't post it cause I put the seal backwards, but to prevent anyone else from doing it make sure you double check your seal when your taking it off, the writing should be UP and the spring DOWN!!!

Most of this is a repeat process but I hope the pics will help someone... Remove front assembly (unbolt stay, unplug wires,unbolt fairings) then wheel...



Unbolt triple tree bolts, upper tree bolts and slide out the fork tube...
*CHECK all your settings and write them on the fork or a piece of paper so you can put it back to where it was when you took it of (The video will show you how to do this correctly if you aren't sure)!!!

untwist the top cap (size unknown) and drain for a few minutes so you don't get soaked with oil when you pull it apart...

**Now I am unsure if you are supposed to set the preload all the way down before or after you remove so if anyone knows please verify so I don't give out the wrong info please



Now use the spring compressor (after setting preload down, in pic it is shown up, and you can't access it)...



Remove top cap, washer,then spring, rod, washers at the bottom of spring, and drain the rest of the fluid for 10-15 minutes....
**( this pic is shown with preload down and nut accessible,)


Remove the dust cover...

[DESE]

Remove old seal...



Now when replacing new seal you can put the fork leg back on and use the PVC method to put on (recommended) or use the old seal and lightly tap the new one on, then grease the new seal before putting the tube back in...This is how the video did it so I used this method...



Now reassemble and pour in your new oil, bleed and use the fork oil tool to get the right oil level ...



After reassembling the forks make sure you put the settings back to what you wrote them down and you should be good to go....

**Sorry for the lack of pics, I planned to redo this maybe sometime this week so when I do I will make a better write up and replace this one, but this is for the people attempting this weekend if I can't get to mine

[LouisR6Raven]

Great write up. Definitely worth saving a few hundred.

[RiceBurner]

going to do my 01 r6 fork seal install this weekend. Hopefully this is relatively the same process. Thanks for the write up!

[Nick18]

Awesome timing with this write up!!

[DESE]

Thanks!!! The r6 fork is almost exact same, only difference is you have to set the preload all the way down to get to the jam nut, I kinda used channel locks with a lip on it, then realized how dumb I was and set the preload down and the nut is accessible ! I will put up some pics when I redo mine...Yes I said redo, MAKE SURE YOU PUT THE SEAL RIGHT SIDE UP !!! LOL !

[RiceBurner]

Originally Posted by DESE

Thanks!!! The r6 fork is almost exact same, only difference is you have to set the preload all the way down to get to the jam nut, I kinda used channel locks with a lip on it, then realized how dumb I was and set the preload down and the nut is accessible ! I will put up some pics when I redo mine...Yes I said redo, MAKE SURE YOU PUT THE SEAL RIGHT SIDE UP !!! LOL !

ahh thats frustrating

[YZF-202]

nice write up and your right with saving money plus you have the tools for another time, care to help out with doing mine lol