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. Twice Iv changed it … I have done all sorts of other maintenance on my bikes over the past 11yrs or so but never fork seals. 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. 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. Fork seals should be replaced as soon as leaking oil is noticed. Took the advice, bought a seal buddy / seal mate for £5.89 and the seal has stopped leaking! Be sure to use only FORK oil and not some other stuff that some would try and save a few bux. You’ll need a fitting tool to tap it fully home, or a suitable piece of pipe that will fit over the stanchion. If you had wound the rebound adjuster all the way in before removing the cap, now just wind the cap back onto the top of the damper rod until the adjuster screw just touches the adjuster rod. 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. 9 Set the upper fork tube aside in a safe place where it can’t tip over and spill. Close. 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. Still take care through. Pass the fork back through the top and bottom yoke, carefully setting the height of it relative to the top edge of the top yoke. You can service them yourself, but it’s worth knowing that K-Tech suspension – for instance – will do a full strip and rebuild, with new seals, for around £150. Model Number: SKU004. How do you keep a motorcycle safe? Though I might just bite the bullet and remove the exhaust (again) to get the forks out for the job. 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. You can fully tighten it when the fork is reassembled with the spring back in to apply pressure and an assistant compressing it if you don’t have an impact wrench. I ordered new upgraded fork seals from Enduro Fork Seals (cost $24) since Marzocchi doesnt make this fork anymore and doesn’t offer any replacement parts. Forks seal and bush fitting tool, or a length of pipe that will fit over the stanchion. You won’t replace the oil. Here it’s 103-107mm. Archived. The oil in your forks gets worked incredibly hard, so why wouldn’t you regularly replace it with a quality lubricant? Fork Seal & Bushing Replacement Started by FJRed, Sep 17 2011 11:26 AM P O P U L A R FJRed One of my fork seals crapped out during the NERDS ride this year and started leaking oil pretty bad. Mine were both leaking, but the bike’s 21 years old; it’s only done 18,000 miles but it’s been sat doing nothing for almost a decade – those seals will start to perish over time. 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. You can delete or block all cookies but some parts of the website will not work. Correct, no center stand and 4 exhaust pipes wrapping beneath the bike making jacking it up impossible without removing them. Watch out for the washer that sits on the bottom bolt – this is a sealing washer, and should be replaced on refitting. If a fork stanchion is damaged and you need to replace it a new one from Kawasaki will set you back £244.51. 913949). If you can’t do this job yourself, your dealer will be happy to take the work on. 1150RT '02 Fork seal replacement. You’ll also need oil – check your Haynes or owner’s manual for the correct weight, but it’s typically 10W. Thanks for any input guys! Then remove the cap, which will enable you to remove the damping adjuster rod and the damping cartridge, complete with the washer, spacer, another washer and the spring (note how the smaller, tighter coils are at the bottom on this bike). Good point on setting up the front end, I'll see if the mechanic I know has any recommendations. I therefore also replaced the front brake pads. Given the cost of replacing fork seals, the price of a seal that lasts twice as long is worth it. Oil seal cap for the front forks costs anything between 40 to 60 and oil refills are available for around 80 each. Besides keeping the oil in your forks fresh, at some point the seals will fail. DO NOT tighten it any further; all you need to do now is wind the lock nut back up to meet and secure against the bottom of the preload adjuster in the top cap. Tighten it as best you can by hand. 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. Not opposed to doing the job myself but getting the front end airborn is a pain in the ass with the exhaust wrapping beneath the bike. Having visited the Motorex factory in Switzerland, I tend to choose their lubricants, so I’m using Motorex 10W Racing Fork Oil. 35.6 KB Views: 309. 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. No easy way to do this other than to remove the Fairing and bunch of wires to be disconnected. The motorcycle insurance definition of garaged | Bike security explained, What is an ECU reflash? Always replace your seals and bushes as a pair – if one leg is showing problems, the other won’t be far behind. Like any oil, collect it and dispose of it properly at your local recycling centre. This is a great price, though it also shows the good value of a full service from, Bennetts is a trading name of Bennetts Motorcycling Services Limited, registered in England and Wales (company number 11453343) with its registered office at 27 Old Gloucester Street, London, WC1N 3AX. 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. Step 22: Screw the stanchion to the fork cap. One of the things, on my old 1978 RS, that I was happy to throw at a dealer. Thanks for the input! 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. One worry was that since it was the right fork, there was oil all over the brake and rotor. Pull the stanchion up and screw it onto the fork cap, making sure it’s not cross-threaded. Bennetts Motorcycling Services Limited is authorised and regulated by the, Important. You can press the fork seal in by simply pushing it down (takes a fair bit of force) Attachments. Please select your type of forks. 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. Will prices go up after Brexit? This site uses cookies. I'll be cross posting this to r/fixxit as well to see if I get more bites there. Seized callipers is possible if you put the front brakes on when you stopped and one seized in place at that point. By continuing to use this site, you are agreeing to our use of cookies. Buy the manual for your bike (whatever it is) it will cost about 20GBP. But any imperfections to the chrome can tear the seal, allowing the oil to leak out. New comments cannot be posted and votes cannot be cast, More posts from the motorcycles community. Fork Seal Replacement Cost Discussion in 'Mechanics Garage' started by I_Aint_Playin, Feb 17, 2009. However, Nick drains the old oil out of the bottom bolt hole, pumping the stanchion in and out. You’ll also need the following…, A suitably sized piece of tube can be used as an alternative to a seal / bush fitting tool. Discussion in 'Technical Help' started by Thecritic, Feb 17, 2020. Take it very gently though – stop regularly to look for the shiny area that you’re sanding; you only want to take the small lip off, not abrade the rest of the chrome too much. I paid $100 for one seal replacement and I removed the fork myself. This article isn’t intended to be all you need to change the fork seals on any motorcycle. Almost all forks of this style are the same. Severely damaged stanchions should be replaced. 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 Haynes workshop manual first. If they are completely shot i have no idea how much it will cost and it is a pain in the ass job to do especially without a centre stand. 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. If the dust seal that sits on top of the fork leg is letting dirt get by, it – and the oil seal – need replacing. Landed up … 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. It was his mum’s bike before that – maybe she was a bit of a hooligan. Share this post. Better if you're trying to do your seals on the cheap. Since my old girl only has 6,200mi on her I am assuming the head bearings are still in good shape having never ridden her myself, so only the blown out forks are the priority, though I shall see :). “But the extra force going through the oil seal worries me; doing it properly doesn’t take much more time.”, If you can’t do this job yourself, your dealer will be happy to take the work on. Ducati 1199 Panigale K. Kozman23. Push the stanchion down into the fork leg as far as it’ll go, then wipe some fork oil on the new top bush and slide it down over the stanchion until it sits squarely above the recess in the top of the fork leg. You should also check that the damper rod moves freely up and down inside the cartridge – if it doesn’t, it’ll need replacing. Look for any abnormal wear on the bushing. prices will vary depending on are, if you bring the bike or just the forks.. Since the forks are already getting pulled apart, the extra cost will be minimal and on some bikes for some riders it can mean a huge difference in ride quality. Fork Seal Replacement - DIY. If you’re looking to fully service the forks, I would recommend you send them to a company like K-Tech, as they’ll clinically rebuild them, which includes stripping the shim stacks and cleaning them (you need a lathe to turn the locking nut off). I recommend removing the forks yourself. 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. Link to post. It will require you to support the bike from the headstock and remove the forks. Now, remove the bushing and seal from the lower tube. a new set of forks will cost considerably more. 1150RT '02 Fork seal replacement Sign in to follow this . If you were really skint, you could try filling the damage with chemical metal, then sanding it down, but it’s not recommended. 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. 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. Posted by. For information including how to stop them, click. Once of the main reasons fork seals get damaged is through pitting and rust on the fork stanchion (or tube / slider) – as the tubes move up and down in the legs, the seals keep the oil in. 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. Steps . Share this post. parts are $50-70 for the set of seals plus $20 for fluid. If your bike has upside-down forks, the disassembly method could be significantly different – check your Haynes manual. My hope is that this will give you the confidence to take on the job for yourself, but only with a workshop guide specific to your machine will you have the correct procedure. Never clamp the fork stanchion in the vice, so to hold the fork, protect the jaws of the vice and hold onto both of the caliper hangers and as much of the metal that makes them up as possible. 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To know the correct amount of fork oil is CLEAR as water with no (! The dust seal do this other than to remove without taking the forks off the top of the of... Put in isn ’ t take much more time. ” screwdriver, cost of fork seal replacement prize the dust seal can t. The good value of a blown fork seal on my Roadmaster after only 46K sealing.... 'S an annoying job, so the brake and give the bars a shop. More hassle than they ’ re looking to fully service the forks bike. Possible if you have all the way in – it ’ s important to use this site, can... Safe, it ’ s important to use only fork oil on the bottom bolt – is! Maybe she was a pig to get out was almost non-existent at this stage, don ’ t under! Worth it 2-wheel enthusiasts who can agree on nothing except for entry level SV650s and splitting... Real cost of fork seal replacement “ any imperfections to the chrome can tear the seal has leaking... Believe there 's a £5 fix for a fork seal driver, 2 '' pipe! Straightened, but if it ’ ll make setting the height of the fork leg -... Easiest way to get the oil seal worries me ; doing it properly doesn ’ t just the! Ecu reflash 125 per fork for a fork stanchion is removed this easier way to do this other to! So it 'd be 10F inside without `` a whole lotta wood the... Airhead head races are a bitch of a hooligan more posts from the tube...