First Fork Seal Replacement (for me)

My fork seals are leaking slightly. I have tried to clean them with the equivalent of a film strip but they still seem to leak a little. Bike is two years old so I am just going to replace the fork seals and dust seals... I need to learn how to do this anyway. I have searched and watched all the videos provided so I think I know what I need to do. Before I place my order I just want to make sure I am getting everything I need for a first time replacement.


Tusk fork seals
Pro-X dust seals
Motion Pro Fork Seal Driver
Fork Oil Level Tool
1 Liter of Yamaha 01 fork oil

Yopu're gonna need a way to hold the damper rod.

Chrispy1200 wrote:

Yopu're gonna need a way to hold the damper rod.

What will I need for that?

Ah, see it now in the shop manual. The aptly named Damper rod holder.

So I found it in the manual, but cant seem to find it on rockymountainatv.com. Anyone know where I can get the one I need?

http://www.motionpro.com/motorcycle/partno/08-0117

Appreciate it.

RattTongue wrote:

My fork seals are leaking slightly. I have tried to clean them with the equivalent of a film strip but they still seem to leak a little. Bike is two years old so I am just going to replace the fork seals and dust seals... I need to learn how to do this anyway. I have searched and watched all the videos provided so I think I know what I need to do. Before I place my order I just want to make sure I am getting everything I need for a first time replacement.


Tusk fork seals
Pro-X dust seals
Motion Pro Fork Seal Driver
Fork Oil Level Tool
1 Liter of Yamaha 01 fork oil

Hi RattTongue,
1 litre of fork is not enough, you will need 2 litres,
each fork leg can hold between 600-700cc , depending on what level you set them to,
you allso dont need to use 01-suspension oil . There are better 5w grade oils to choose from.
hope this helps
V-tec

v-tec wrote:

Hi RattTongue,
1 litre of fork is not enough, you will need 2 litres,
each fork leg can hold between 600-700cc , depending on what level you set them to,
you allso dont need to use 01-suspension oil . There are better 5w grade oils to choose from.
hope this helps
V-tec

Thanks for the heads up. I was only using yamaha 01 because I wasn't sure what a good replacement would be. Is yamaha-01 5w? So I could use 5w Bel-Ray instead?

[quote="RattTongue"]

v-tec wrote:

Hi RattTongue,
1 litre of fork is not enough, you will need 2 litres,
each fork leg can hold between 600-700cc , depending on what level you set them to,
you allso dont need to use 01-suspension oil . There are better 5w grade oils to choose from.
hope this helps
V-tec

Thanks for the heads up. I was only using yamaha 01 because I wasn't sure what a good replacement would be. Is yamaha-01 5w? So I could use 5w Bel-Ray instead?[/quote

Yes yam 01 is 5w
Bel-ray will be fine,or any good named brand.

v-tec

I am in the middle of replacing my fork seals. I have the fork completely disassembled. Now that I do it looks like it is NOT necessary to remove the damper rod and base valve just to replace the fork and dust seals. Especially considering that according to the shop manual the first step to reassembly is to re-install the damper rod BEFORE installing the seals and outer fork. Am I missing something?

One leg of the fork started to leak after few cold month in my garage. Season is coming. Do I have to worry about it and what need to be done? My bike has only 3000 km mileage.

I'm not an expert, I can only regurgitate what I have heard/done. You might try inserting the corner of a business card between the seal and the inner fork and running it around to clean it out. To do this you have to drop the dust seals down to get to the fork seals. When mine started leaking and I asked my brother-in-law (who is an expert) about it, his question to me was "has it been sitting a while?". In other words, cleaning it out might not help. When I asked if it was something I needed to worry about he said basically only if its leaking really bad and only if you get tired of the mess and constantly having to check/add fork oil. In other words might was well replace them. Aside from the initial expense of buying a fork seal driver it is really not all that expensive and once you do it you will realize how incredibly easy of a task it is to perform.

Thanx. Mine fellas sad its not so bad. It's all about winter and it's better to store it on a stand.