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Fork Seal Replacement


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Fork Seal Replacement

 

The manual will tell you to remove the fork assembly from the Bike, but this is not necessary! What I will explain is in my opinion is the fastest way to do the job.

 

Special Tools needed

Impact wrench (electric or air )

17 MM hex head socket

8 or10 MM hex head socket (Most are 10mm but I have found 8mm)

Last but not least you will need a tool to insert the seal into the fork body. Yamaha sells a tool, but it won’t work with this procedure, I made mine. See photo “tool”

The rest of the tools needed come in the bike tool kit.

 

To start:

Place the bike on the center stand and a floor jack under the motor for safety.

Remove as much air as possible from the front forks. { this is very important!}

There is a small screw on each of the forks facing outward, this screw will let oil come out when removed and will let the rest of the pressure out, so unless you want a bath have a container ready.

Remove the front brake calipers, wheel, and fender

Place a container; pan something to catch the oil when you do the next step.

Using an 8 or 10 MM allen socket and impact wrench remove the bolt at the end of the lower tubes. Remove the fork brace.

Raise the dust cover on the first tube (small screw driver will work)

Use screwdriver to remove the locking ring under the dust cover.

Remove the plastic cover on the steering head and (86-93 disconnect the plug for the lights.)

Remove the grills on both sides of the steering head.

Remove the handlebars from the steering head (you don’t need to remove or disconnect anything just put them to the side)

Remove the plastic/rubber covers on the fork tube caps.

Loosen the 2, 12 MM headed bolts (or cap head bolts on later models) at the top brace on each side.

NOW BE CAREFUL! Using the 17 MM hex head socket and what I call a speed wrench; stand on the foot pegs positioning your self so that the end of the speed wrench is against you shoulder when you loosen the tube caps. The caps have fine treads and are spring loaded so again be careful.

Remove upper assembly & the spring on Yamaha springs or the plastic spacer and springs on Progressive springs for cleaning.

Now to remove the lower tube by using it as you would the weight on a slide hammer, they don’t come off easy so start out easy and increase force until the two separate. When they do come apart; clean the inside of the lower tube be sure to note how the small pieces fit!

If they are not put back the way they came out the anti-dive won’t work…

Now remove the bad seal and replace it with the new one, be sure to use a little oil on the seal before installing it on the tube. Note to remove the old seal you have to remove the upper and lower bushings, silver washer, seal and gold colored washer when you put them back keep them in the same order.

Reassemble in reverse of the above.

You will need 13.5 oz of 10 or 15 WT fork oil for each tube.

If the bike has a lot of miles or you live in hot country use 15WT

 

Good luck and ride safe

 

 

If you have a problem you can e-mail firstgen@mtariders.com or call 775-751-2169

 

 

Fred Vogt

 

 

 

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tool

 

image006.jpg

 

 

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  • 8 months later...

Additional Pictures Submitted by GeorgeS

Click on any image for a larger picture.

http://www.venturerider.org/forkseals/george/1%20(WinCE).jpg http://www.venturerider.org/forkseals/george/2%20(WinCE).jpg http://www.venturerider.org/forkseals/george/2b%20(WinCE).jpg

http://www.venturerider.org/forkseals/george/3%20(WinCE).jpg http://www.venturerider.org/forkseals/george/4%20(WinCE).jpg http://www.venturerider.org/forkseals/george/5%20(WinCE).jpg

http://www.venturerider.org/forkseals/george/5b%20(WinCE).jpg http://www.venturerider.org/forkseals/george/8%20(WinCE).jpg http://www.venturerider.org/forkseals/george/9%20(WinCE).jpg

http://www.venturerider.org/forkseals/george/10%20(WinCE).jpg http://www.venturerider.org/forkseals/george/11%20(WinCE).jpg http://www.venturerider.org/forkseals/george/12%20(WinCE).jpg

http://www.venturerider.org/forkseals/george/12b%20(WinCE).jpg http://www.venturerider.org/forkseals/george/12c%20(WinCE).jpg http://www.venturerider.org/forkseals/george/13%20(WinCE).jpg

http://www.venturerider.org/forkseals/george/14%20(WinCE).jpg http://www.venturerider.org/forkseals/george/14b%20(WinCE).jpg http://www.venturerider.org/forkseals/george/14c%20(WinCE).jpg

http://www.venturerider.org/forkseals/george/14d%20(WinCE).jpg http://www.venturerider.org/forkseals/george/15%20(WinCE).jpg http://www.venturerider.org/forkseals/george/15b%20(WinCE).jpg

http://www.venturerider.org/forkseals/george/16%20(WinCE).jpg http://www.venturerider.org/forkseals/george/17%20(WinCE).jpg http://www.venturerider.org/forkseals/george/17b%20(WinCE).jpg

http://www.venturerider.org/forkseals/george/18%20(WinCE).jpg http://www.venturerider.org/forkseals/george/19%20(WinCE).jpg http://www.venturerider.org/forkseals/george/20%20(WinCE).jpg

http://www.venturerider.org/forkseals/george/21%20(WinCE).jpg http://www.venturerider.org/forkseals/george/22%20(WinCE).jpg http://www.venturerider.org/forkseals/george/23%20(WinCE).jpg

http://www.venturerider.org/forkseals/george/24%20(WinCE).jpg http://www.venturerider.org/forkseals/george/24b%20(WinCE).jpg http://www.venturerider.org/forkseals/george/25%20(WinCE).jpg

http://www.venturerider.org/forkseals/george/26%20(WinCE).jpg http://www.venturerider.org/forkseals/george/27%20(WinCE).jpg

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