Ok, gonna do it next week and need just a quick rundown on what I need. New fork seals, oil, etc. Special tools? I've torn apart many a MX bike in my day, but you guys have done this a thousand times now I want the skinny on what the quickest and easiest way to do this. I plan on doing it in an afternoon and getting it over and done with.

I've had the lowers sitting in the garage for months now, and I'm going on a trip at the end of June so I need it done and over with.

Thanks ahead of time - Jon

 

Also, which oil is recommended, S/E or other?

 

I got this from dawg. I hope he doesn't mind me sharing. Thanks dawg, great info.



I'm going to assume that you have a service manual and don't need to know the basics like removing the wheel, fender, outer fairing, ignition switch, etc.

Once you have the fender off you will need to remove the 6mm bolt on the bottom. It is easiest to do this with an air impact wrench, but I didn't want to get out my compressor, etc. so I went a different route. You will need a long 6mm allen head socket. I made one by cutting off a 6mm allen wrench and epoxying (JB Weld) it into a socket

Then I used a flatblade screwdriver and put it through one of the caliper mounting holes to hold the fork while I ratcheted off the 6mm bolt in the bottom of the fork tube. Have a drain pan underneath because that's where all the fluid will come out.

Once these bolts are out you can then give a couple of good hard jackhammer pulls up and down and the fork leg will come down. Remove the oil seal retaining ring

Once the leg is off you will have the oil seal and slider bushing and washer still on the fork. If you want to remove them from the bottom, you can put a screwdriver in the slot on the retainer and "pry it open gently" to release it from it's groove.

The oil seal can then be taken off and discarded. The 6mm bolts should be discarded and you should use new bolts and copper washers. You can take off the upper cow bells by undoing the two bolts that holds them on

Put on the chrome cowbells and then put the new oil seal onto the fork and put the parts back on the bottom. Slide the chrome lower up and push it up. You can take a PVC coupler and grind it down so that it fits into the lower leg and cut one side so that you can open it up to get it around the leg

This will act like one of the split 41mm fork seal installers. You can then use that to seat the seal in the lower leg and reinstall a new retaining clip. If you cannot do this you would have to remove the fork from the triple tree. To do that you would release the pinch bolts and unscrew the 36mm fork cap bolt in the top where the oil goes.

and pull the fork down out of the triple tree. It will pull down through the rubber fork stops as well. Sometimes it is easy to spray some windex or silicone onto the forks around the rubber to make it slide easier

Then you could use that PVC coupler and another piece of PVC on top to "hammer it" down to seat the seal

Then you reinstall the fork and install new fork cap seals and make sure the new chrome fork drain screws are installed and fill with oil per the manual. I used a James Gasket kit that included everything I needed


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