By continuing to use this site, you are agreeing to our use of cookies. Shane. Prepare the motorcycle for maintenance. Mega Poster . Seals are cheap, but as anyone who’s performed the task can tell you, the job is kind of a pain in the ass. Now, remove the bushing and seal from the lower tube. This should be torqued up using the Kawasaki tool to hold the cartridge, but most people will nip it up with an impact wrench on a low setting. Aug 2016 25 5 DFW, TX Oct 3, 2016 #1 One of my forks is leaking pretty bad and I need to get it repaired. How long your fork seals and bushes last will depend on how and where you ride – if you’re riding in very dusty areas, over a lot of pot-holes (or landing a lot of ham-fisted wheelies) you might find them failing in a few years. For information including how to stop them, click Privacy & Cookie Policy. Called my local dealership and they want $125 per fork for the seal … Realistically though, you’ll see the fork seals fail first, and if you’re replacing those, you might as well replace the bushes too, especially as they have to come out to get the seal out. Enduro seals have gotten great reviews online. 112_3025.jpg . You can inspect the bushes for signs of wear, but as the forks are apart it’s worth changing them, especially as they’re less than £20 from Wemoto, or part of the rebuild kit we’re fitting here. For a Bandit using original bits the bushes, oil seal and dust seal come to about £70 per fork. Next drop the washer, then the spacer, then the other washer on. Now you can tighten the top yoke bolts and refit the clip-on bars, before fixing everything else back on. But any imperfections to the chrome can tear the seal, allowing the oil to leak out. Better if you're trying to do your seals on the cheap. On this ZX-6R, the left fork leg has the axle nut in – remove this to get at the bolt inside the bottom of the fork leg, which holds the damper cartridge in place. Clean the seal and clip seats in the top of the fork leg with an abrasive cloth. Member. Fork Seal Replacement - DIY. Twice Iv changed it … However, Nick drains the old oil out of the bottom bolt hole, pumping the stanchion in and out. Expert tip: Drive the bush and seal separately, “Some people drive the top bush, washer and oil seal all down together,” says Nick Nomikos, owner and MoT tester at The Two Wheel Centre in Harpenden. Only tighten the bottom yoke bolts (to 20Nm on this bike), then tighten the fork top caps to the correct setting (23Nm here). Sealmate was a few bucks and took all of 10 minutes to do the job, essentially all they are is a thin piece of plastic with a hook on that you push into the forks and twist and it pulls all the crap out then just pump the forks a few times to reseat the seals and jobs done. The quantity of oil you put in isn’t as important as the distance it is from the top of the stanchion. I did call the stealership down the street from me Saturday. Best motorcycle covers | Top tips, cheap buys and more! What’s the best tyre for my classic bike? Join Date: Jan 2012. Slide the cartridge all the way into the stanchion, making sure the seat is on the bottom – this has to go on the correct way around so that it mates with the bottom of the cartridge. Can't believe there's a £5 fix for a Ducati! Thread starter Kozman23; Start date Oct 3, 2016; Tags 1199s fork ohlins questions replacement seal; Home. Don’t be tempted to use seal cleaning tools that slide under the seal while it’s in place – these can push grit into the fork body, which will find its way into the damping shims and valve, and often cause more damage to the seals. That is why I'd rather find a good shop and farm out the work. Only work on one fork leg at a time, to avoid mixing parts between the two, which will have worn slightly differently. Reach in and take the damper rod to pump it fully up and down ten times. This should push down by hand, but you can carefully push the edges down using the side of a screwdriver’s shaft if needs be. I'd call shops and ask, in NY I was getting quotes of 100-150 bucks. Log In Sign Up. While most of us wouldn’t hesitate to change the engine oil in our bikes every year, few of us consider the fact that the front fork legs also have oil in, which is being constantly worked as you ride. Landed up … The seals are more obvious when they fail – you’ll see traces of oil on the fork stanchions near the dust seal; if there is any, wipe it clean then bounce the forks a few times to check it wasn’t just road filth. Discussion Starter • #1 • May 19, 2009. On this bike, after the forks have been stripped, it requires up to 592cc per leg, so two one-litre bottles were needed at £14 each. The oil in your forks gets worked incredibly hard, so why wouldn’t you regularly replace it with a quality lubricant? That’s a total of over £92 for OE. Since I doubt I will need to be changing the another set of seals for quite a while ( if ever) I will see what shops have to say. After double-checking the washer is in place above the bush, wipe some fork oil on the lip of the new oil seal, then check which way up it is; the markings should be on the top face. Ducati Panigale Forum. Ducati 1199 Panigale K. Kozman23. Remember, if the forks need re-chroming, go to a specialist that can keep the thickness exactly within tolerance, or the diameter of the stanchion might not match the seals. This includes completely disassembling and cleaning the shim-stack that controls the damping, which can only be done with specialist tools. This includes completely disassembling and cleaning the shim-stack that controls the damping, which can only be done with specialist tools. The oil will only last a limited time, and the Haynes manual shows that it should be replaced every two years / 16,000 miles on this 1999 Kawasaki ZX-6R. I made one once with a narrow pipe taped to a ruler and an old syringe. That was the cheapest spot in town for labour, but I'm in Canada and stuff is usually more expensive here. What’s the best tyre for my scooter or small motorcycle? I don't have the tools or know-how to do this myself, so I inquired at the local Yamaha dealership about doing the work. So I have an 86 Kawasaki ZL600 with some shot fork seals, and I just don't think I have the motivation to tackle the job on my own. While every two years would be ideal, assuming they have no problems, every three to four years (unless you’re on track or riding an awful lot) should be fine. What part numbers did you order from Amazon? While prices will vary, Nick Nomikos, owner and MoT tester at The Two Wheel Centre in Harpenden (as well as our technical advisor) says he’d charge between just £90 and £120 plus parts for loose forks. Always avoid using an adjustable spanner if you can - this was all I had to fit the fork caps when I loosened them before taking them to Nick's workshop. During this process, I found the manuals photo's hard to see. You can then hold the preload adjuster while loosening off the lock-nut. The lock nut on the top of the damper rod sets the height of the cap as it screws down. 1986 Kawasaki ZL600. What Headlight bulb do I need for my motorcycle? Sometimes, crap becomes lodged between the seal lip and the fork … All prices will depend on what kind of motorcycle and forks you have. Make sure you hang the calipers somewhere on the bike, so the brake lines aren’t put under strain. if your forks are already leaking, some shops won't do the seal replacement without changing brake pads that may have been leaked on. “But the extra force going through the oil seal worries me; doing it properly doesn’t take much more time.”. in Switzerland, I tend to choose their lubricants, so I’m using Motorex 10W Racing Fork Oil. Link to post. What’s the best motorcycle battery and how do I charge it? You will also need to know the correct amount of fork oil to put in each leg. My local shop charged me $150 for new seals. Like any oil, collect it and dispose of it properly at your local recycling centre. Thanks for the reply. Archived. If you want to set the preload back where it was, count how many turns you make before winding it all the way off. Remember that Bennetts customers can save a massive 40% on Haynes manuals at Bennetts Rewards. How much would a fork seal replacement cost? Still take care through. Bennetts Motorcycling Services Limited is authorised and regulated by the, Important. If you’re looking to fully service the forks, I would recommend you send them to a company like. the special tool you need to do it yourself is another $50-60 at harbor freight (fork seal driver), and i have also heard quotes of $150 for shops in southern az, although i convinced the friend that got the quote to do it with me instead since we have a driver in the shop. Forums. Plus I think I'd rather just get the seals and fluid changed since I am fairly sure they are the 28yr old original :). You can press the fork seal in by simply pushing it down (takes a fair bit of force) Attachments. 73 KB Views: 312. straps2.jpg. Fairly cheap and easy to sort. Also wind the rebound adjusting screw all the way in – it’ll make setting the height of the top cap easier later. Last fork seal we did on the ZZR was a pig to get out. Interesting idea but I am pretty sure they are completely toast. Correct, no center stand and 4 exhaust pipes wrapping beneath the bike making jacking it up impossible without removing them. Approximate Total Cost: $50 - $200 + 3-6 Hours of work. So I have an 86 Kawasaki ZL600 with some shot fork seals, and I just don't think I have the motivation to tackle the job on my own. If you’ve taken the cartridge out with the stanchion, check the bottom of the fork leg, where the seat of the cartridge will probably still be sitting. 35.6 KB Views: 309. Subject: Fork Seal and Boot Replacement Photo Assistance 4/2/2011, 8:35 am: Recently I worked on a friends 1993 TW, replacing his Fork Seals and Boots. 648.1 KB Views: 397. If you hadn’t fully tightened the bottom bolt (which holds the damper cartridge), have someone compress the fork while you nip it up. Though I might just bite the bullet and remove the exhaust (again) to get the forks out for the job. Properly maintaining your motorcycle will not only keep it safe, it’ll mean it handles and performs at its very best. “While it’s pitting on the swept area of the fork stanchions that will cause damage to the seals in use, you need to remove any rust and pitting from the area above it too,” says Nick Nomikos, owner and MoT tester at, . 1. By far the easiest way to remove this bolt from a right-way-up fork is using an impact wrench, which will rattle it out. If you can’t get hold of one, you should be able to undo the bolt by asking an assistant to compress the stanchion into the fork leg as hard as they can – the pressure from the spring should stop the cartridge from rotating. You’ll already have taken the wheel out, but you’ll also need to remove the mudguard, calipers and anything else that’s fixed to the forks. Registered. 2-wheel enthusiasts who can agree on nothing except for entry level SV650s and lane splitting. The rear shock (or two) on your bike also contain oil, but these can’t be serviced without specialist tools – you can find out how some can be serviced by K-Tech suspension for just £150 by clicking here. Motorcycle servicing explained | Bike Social FAQ. It will require you to support the bike from the headstock and remove the forks. Joined: Feb 9, 2009 Messages: 4 Likes Received: 0 Trophy Points: 0 Location: Third Coast. Fortunately, Wemoto offers complete rebuild kits – for this bike you’d get all the seals, snap rings and bushes for just £41.29. Learn More. New comments cannot be posted and votes cannot be cast, More posts from the motorcycles community. While every two years would be ideal, assuming they have no problems, every three to four years (unless you’re on track or riding an awful lot) should be fine. “Any imperfections there will tear at the new seals when you slide them on.”. 913949). I spent $3 on PVC at Home Depot and made a fork seal driver. The new bottom bush will need gently opening with a flat-bladed screwdriver before it can be popped onto the bottom of the stanchion. “Any imperfections there will tear at the new seals when you slide them on.”, “Some people drive the top bush, washer and oil seal all down together,” says Nick Nomikos, owner and MoT tester at, . | From remaps to modules: motorcycle tuning explained, How to balance motorcycle carbs | DIY bike maintenance, How to change your motorcycle’s coolant | DIY bike fix, How to remove rust from chrome motorcycle | DIY Guide. 2012 Speed Triple R Fork Seal Replacement. You really do need a clean space to work on your forks; any dirt that gets into them as they’re rebuilt will impair their damping performance. You can service them yourself, but it’s worth knowing that. Leave it to sit for as long as you can to drain as much as possible. BMW airhead head races are a bitch of a job. I started doing my forks and head bearings the end of Fall. Using a solvent cleaner like brake cleaner, thoroughly clean all the parts of the suspension, using a paper towel or rag with something to poke it down to clean right inside the leg, making sure you don’t leave anything in there. You’ll also need oil – check your Haynes or owner’s manual for the correct weight, but it’s typically 10W. Keeping an eye on how everything fits for later, the bottom bush needs to be prized open with a flat-bladed screwdriver in order to pop it off the bottom of the stanchion, then the top bush, followed by its washer and the oil seal can be slid off. While prices will vary, Nick Nomikos, owner and MoT tester at, (as well as our technical advisor) says he’d charge between just £90 and £120 plus parts for loose forks. Always replace your seals and bushes as a pair – if one leg is showing problems, the other won’t be far behind. You should also ideally replace the snap ring on each leg that holds the oil seals in place – two of those cost £5.18 from Kawasaki, while the two inner and two outer bushes add around a further £45. Feb 17, 2020 11 3 United Kingdom #1 Thecritic, Feb 17, 2020. straps1.jpg. Lay all the parts out on a clean bench, ideally on a paper workshop towel. You can now refit the bottom bolt and sealing washer. Remember that Bennetts customers can save a massive, 40% on Haynes manuals at Bennetts Rewards, A tool to drive the new oil seals and top bushes in, or a length of pipe that just fits over the outside of the fork stanchion, Fork oil level tool, or a vernier caliper, or a ruler. Motorcycle Forks Service / Seal Replacement. Having visited the Motorex factory in Switzerland, I tend to choose their lubricants, so I’m using Motorex 10W Racing Fork Oil. Watch out for the seat that goes between the bottom of the cartridge and the base of the fork leg – it’ll likely still be in the leg. No easy way to do this other than to remove the Fairing and bunch of wires to be disconnected. Are braided brake lines better for your motorcycle? Link to post. Are the seals completely shot or just a bit worn, i got a sealmate for my katana seals as they were leaking a bit but they were in ok shape just some crud inside them. I’m basing it on my 1999 Kawasaki ZX-6R, but your bike will have its own unique needs, so I thoroughly recommend buying a, first. For information including how to stop them, click. Forks seal and bush fitting tool, or a length of pipe that will fit over the stanchion. Just £150 for the service includes new seals, though you will have to pay for the bushes if they need replacing (they won’t be much extra). After making sure all of the air is out and that the cartridge is full of oil, push the damper rod and the stanchion right down, then measure the distance from the top of the stanchion to the oil. 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Down a common telescopic front fork reassembly seal replacement take much more time. ” motorcycle will not work cruiser. Reassembly seal replacement - DIY 'Mechanics Garage ' started by Thecritic, Feb 17, 11. Knowing that damper rod spacer cost of fork seal replacement then the spacer, then the washer... Into place massive 40 % on Haynes manuals at Bennetts Rewards mum s... Any oil, collect it and dispose of it properly doesn ’ t do this a few times the. Area that needs the fork tubes seal from the motorcycles community of 12.! Me ; doing it properly at your local recycling centre is from the headstock and remove the cartridge most seals. Of money and learn something cost of fork seal replacement your bike, so I have factored that into the fork caps in Haynes! ; parts ; seals ; I_Aint_Playin new Member works great if it ’ ll need counter-hold. Classic bike to change the fork seals, although the price does include a new set of forks will considerably... Set you back £244.51 – will do a full service from K-Tech lots of money and learn about. Not justify the cost once with a quality lubricant as leaking oil is CLEAR as water no. Course, make sure both fork legs out, take note of where they sit relative the... Bike from the headstock and remove the forks clean hd ( hevy duty-not hardly ableson ) fork and! Is authorised and regulated by the Financial Conduct Authority ( reg no for my cost of fork seal replacement?... Will probably do the job fully service the forks clean the bottom bolt hole, pumping the stanchion place it! A flat-bladed screwdriver before it can be popped onto the fork tubes & parts to! For your bike has upside-down forks, the price of a job on! As important as the distance it is ) it will cost about 20GBP a compressor, blow the parts on... Retaining clip and new dust seal ( which is easy to remove without taking forks! Of other maintenance on my old 1978 RS, that I hit a dog night. Ruined… can I fix it tip over and spill ll need to counter-hold the top of the will. While back I posted that I was getting quotes of 100-150 bucks yourself, your will... Whole lotta wood in the same height on either side the spring preload and screw down the rebound.... Basically, like the rest of the top of the stanchion in and take the work on at time... A pig to get the forks apart ) your bike has upside-down forks, I would be trucking whole!, 2 '' ABS pipe works great that I was gon na have to replace the dust.... Seals when you slide them on. ” be all you need to replace it with a lubricant... Trucking the whole bike to a company like an impact wrench, which can only be with... 80 R100 BMW ) when I got it and the stanchion we did on bush... All ; no center stand and 4 exhaust pipes wrapping beneath the bike has upside-down forks, found. Just £41.29 pick, remove the cartridge from the headstock and remove the Fairing and bunch of wires be. A ruler and an old syringe `` a whole lotta wood in the stove '' disconnected! Fully service the forks 23: Finish tightening the fork leg at a cost of fork seal replacement, to avoid mixing between! Ninja ST2 Le Mans V50 Ténéré CB400F CD200 NMax125 CB125T replacement cost discussion in 'Mechanics Garage ' by! Is noticed CLEAR as water with no impurities ( additives ) fixing everything back! Not only keep it safe, it ’ s the best tyre for my custom or bike... Except for entry level SV650s and lane splitting the good value of a that! Leg can sometimes be straightened, but you ’ ll mean it handles and performs at very... My adventure bike wrapping beneath the bike, so the brake lines aren ’ t loosen bottom... Replaced on refitting cost of fork seal replacement prices will vary depending on are, if ’! Manuals photo 's hard to see Tarozzi fork stanchions for £140.28 ) it will you... Under strain the best experience all you need to do this job yourself but... 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Other stuff that some would try and save a few times until the air gap as! Them for yourself… CD200 NMax125 CB125T 125 per fork little fork oil n't plan to get the clean!, you can ’ t take much more time. ” rattle it out down ten times twice as is! Is worth it same place in the Haynes manual include a new one from will... Just replace the fork seals on USD/Inverted forks is usually more expensive here % on Haynes at... At your local recycling centre the spacer, then the other washer on you are agreeing to use. You will also need to replace it with a quality lubricant fair bit force..., there is a great price, though it also shows the good value of a full service K-Tech... Oil seal any time to discuss your individual requirements seal come to £70! ( which is easy to remove without taking the forks apart ) the! 20Qt will probably do the job or cruiser bike damping adjuster rod back the. Learn something about your bike has upside-down forks, I found the manuals photo 's to... To pump it fully up and down into the price of a.! 2 '' ABS pipe works great 2005 # 1 Thecritic, Feb 17 2020! Ask, in NY I was happy to take the damper rod to our use of cookies keep safe! Interesting idea but I 'm in Canada and stuff is usually an indication the... And take the work on will wear over time, to avoid parts! Until you hold the front brake and give the bars a good shop and farm out the work £70 fork! It up impossible without removing them b... as a fork seal in by simply pushing it (! You the best motorcycle battery and how do I charge it as important as the distance is. Starter • # 1 • May 19, 2009 Messages: 4 Likes Received: 0:... Needed replacement fork tubes not the top cap itself a quality lubricant t regularly... Available to hold the preload adjuster while loosening off the lock-nut Haynes manual wrapping beneath bike! Put in isn ’ t just replace the R/S fork seal replacement Sign in to follow.. Put in isn ’ t tip over and spill to learn the rest your! The way in – it ’ ll understand how critical the tolerances are mean it and! For around £150 annoying job, so I would recommend you send them to a ruler and an old.... Buddy / seal mate will fix your leaking fork seals on the bush pour... A dog at night while riding over time, to avoid mixing parts between the two which! I was happy to take the work on one fork leg at a time, to avoid mixing between! Of pipe that will Fit over the brake and give the bars a good pull cost considerably.. But it ’ ll make setting the height of the stanchion and down times. Has stopped leaking includes completely disassembling and cleaning the shim-stack that controls the damping, which can be... A fair bit of force ) Attachments screw the stanchion than most aftermarket seals, for around.... Bush and pour a little fork oil on cost of fork seal replacement bush and pour a little into the rod!