Replaced my fork seals - vid - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

 
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post #1 of 4 Old 08-29-2007, 10:11 AM Thread Starter
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Replaced my fork seals - vid

I needed new for seals to correct a persistent leak in my left fork.

It took a lot of research to figure out how to do it. The main problem was figuring out how to get the old seals out with air. There was a lot of info about what to do but little on how. Thanks to mdrake for giving me the courage to try it. I made a video of the procedure in case others are interested.

While I was at it I replaced the fork boots, greased the front wheel parts, installed Progressive springs and cleaned fork tubes & filled with new fork oil. I was also able to lube the speedo cable while I had the fairing off.



I put the bike up on my portable work stand. Tied down the rear and jacked up the front.
I didnt have to but I removed the fairing for easy access to the pinch bolts. 3 screws and the 2 signals hold it on. Then the brake caliper and brake line guide were removed and tied to the nerf bars. Then the speedo cable and its guide were detached & moved out of the way.



I loosened the fork caps first then all the pinch bolts except the bottom ones. I then held the tube in one hand while I loosened the bottom bolt. The tube slid right out. Same with the other.



I removed the caps from the fork tubes, then the spacers & springs. I then dumped out the old oil and dumped in some ATF and worked the tubes some to clean the insides. I then hung them upside down to drain overnight.



Next morning I started the seal replacement procedure. It was a lot easier than I thought. I did one at a time. After the first the second went faster & easier. I used a piece of 1.5 ABS sched 40 pipe to seat the parts back into the tubes with a few taps with my hand. The video is about 8.5 minutes long.



I put it all back together. A note on the pinch bolts. There are 4 sets, each with 2 bolts. The torque is 18 ft lbs. Double check each set. As one bolt is brought to the proper torque the other in that set loosens some to where it has to be done again. I checked each set 3 or 4 times.



I feel good. Hope I did it right. Lets hope it works.

John

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post #2 of 4 Old 08-29-2007, 11:02 AM
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Nice work!! I know somebody that has been putting off doing their seals..I'm going to e-mail him this thread!!

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post #3 of 4 Old 08-29-2007, 02:40 PM
 
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Originally Posted by larryboy View Post
Nice work!! I know somebody that has been putting off doing their seals..I'm going to e-mail him this thread!!

+1 good work!
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post #4 of 4 Old 08-29-2007, 04:03 PM
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Just a note, I think the pinch bolts have an updated torque value of 14 ft pounds. 18 is okay, but it is right on the edge of stretching the trees.
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