Fork seals - 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 5 Old 01-07-2008, 03:34 PM Thread Starter
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Fork seals

Fork s

Last edited by X6_Hustler; 08-01-2008 at 07:03 PM.
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post #2 of 5 Old 01-07-2008, 03:42 PM
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I've never used any special tools for fork seals. Let out the air pressure up top, drain the oil at the bottom of the fork, put the drain plug back in, put the valve core back in if you took it all the way out, pull the snap ring that hold the dust seal down, hold a rag around the seal area, put air to the valve up top until you pop the seal out. Use a blunt punch to tap the new seal in.
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post #3 of 5 Old 01-10-2008, 09:29 PM
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I use air to remove the seals also. The only special tool I use is a length of pvc to tap the new seal in place. Are you sure the seal is bad? I have had them leak pretty bad before and found that if I cleaned them and put them back in they worked just fine. Sometimes you get some dirt in them and they leak. You may be able to use a piece of film or mylar to ''fish'' the dirt out, without removing the fork. Just slip the film between the seal and fork and slide it around the fork with an upward motion. I'm cheap and don't like to buy new seals if I don't have to.
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post #4 of 5 Old 01-11-2008, 07:27 AM
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Yo Hustler,

Here is a short 4 minute video I made while I did mine. It was my first time working on fork seals. They came out fine.

Hope it helps.
Good luck.


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post #5 of 5 Old 01-18-2008, 07:52 AM
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Good video! Now I know I'm not competent enough to do mine
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