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 Fork Seal and Boot Replacement Photo Assistance

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Admiral
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Admiral

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Join date : 2010-06-08
Age : 58
Location : Sand Hollow, Idaho

Fork Seal and Boot Replacement Photo Assistance Empty
PostSubject: Fork Seal and Boot Replacement Photo Assistance   Fork Seal and Boot Replacement Photo Assistance EmptySat Apr 02, 2011 8:35 am

Recently I worked on a friends 1993 TW, replacing his Fork Seals and Boots. During this process, I found the manuals photo's hard to see. So, to help others who may perform these maintenance tasks where the front forks would need to be removed, I photo documented the process to act as a visual guide to supplement the manual. The photo's are not a step-by-step process, please use the manual for specifics such as: fork oil and amount to use, torques etc.

Additionally, these photo's are from a 1993 model with drum brakes. Models with the disk brakes are similar, but there are some differences with bracket and cable locations, but this should still help.

Also, according to the manual, you will need a T-handle and damper rod holder (basically a nut) to remove the damper rod if you are replacing the seals. I used on-hand tools and fabricated a damper rod holder out of a nut and bolt. This saved me the cost of purchasing the special tools the manual calls for.

Note the torn fork boots in the first photo.
Fork Seal and Boot Replacement Photo Assistance BeforeDisassemblyForks

Photo added for humor.
Fork Seal and Boot Replacement Photo Assistance ToolChest

Fork Seal and Boot Replacement Photo Assistance ForkCapTopPinchBolt

Fork Seal and Boot Replacement Photo Assistance CopyofTWForkRepair015

Fork Seal and Boot Replacement Photo Assistance DirtySeal

Fork Seal and Boot Replacement Photo Assistance CleanSeal

Fork Seal and Boot Replacement Photo Assistance ForkCap

Fork Seal and Boot Replacement Photo Assistance Collar

Fork Seal and Boot Replacement Photo Assistance OilDraining

Fork Seal and Boot Replacement Photo Assistance HMDamperrodtool

Fork Seal and Boot Replacement Photo Assistance HMToolFullFork

Fork Seal and Boot Replacement Photo Assistance OuterTubeHexBolt

Fork Seal and Boot Replacement Photo Assistance HMToolComponents

Fork Seal and Boot Replacement Photo Assistance Damperrodholder

Fork Seal and Boot Replacement Photo Assistance DamperRodEnd

Fork Seal and Boot Replacement Photo Assistance Damperrod

Fork Seal and Boot Replacement Photo Assistance Oldseal

Fork Seal and Boot Replacement Photo Assistance SealRemoval

Fork Seal and Boot Replacement Photo Assistance Donenotdone

For installation, reverse order. Note: Also needed is a seal drive tool. Again I used a tool from on hand tools at home (not pictured). I used a large socket that matched the size of the seal, and installed the seal, retaining clip, I used the drive (socket) to install the dust seal as well. Then I installed the inner fork tube. This is a slight deviation from the mannual, but works just fine as the inner fork tube will slide in nicely if you are careful. Remember to use the lithium grease on the seals as called for in the mannual. Additionally, don't forget to add and measure the proper amount and type of fork oil.

Completed, seals/boots replaced and forks re-installed

Fork Seal and Boot Replacement Photo Assistance NancySinatra
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mrgizmow1

mrgizmow1

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Location : Paradise, Calif

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PostSubject: Re: Fork Seal and Boot Replacement Photo Assistance   Fork Seal and Boot Replacement Photo Assistance EmptyMon Apr 04, 2011 6:16 pm

Hey Kris, that is a Great tutorial..... Thanks, Gerry

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jbfla



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Join date : 2010-09-10
Location : FL, GA, NC

Fork Seal and Boot Replacement Photo Assistance Empty
PostSubject: Re: Fork Seal and Boot Replacement Photo Assistance   Fork Seal and Boot Replacement Photo Assistance EmptyTue Jun 07, 2011 7:42 pm

Excellent documentation, Admiral. cheers

Hope I won't need to use it too soon.

jb
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PostSubject: Re: Fork Seal and Boot Replacement Photo Assistance   Fork Seal and Boot Replacement Photo Assistance Empty

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