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Discussion Starter #1
I'll have to replace the fork seals soon and I have a question about fork disassembly.
With the fork cap undone and the damper rod unscrewed from the cap, can the outer tube be withdrawn from the inner tube with the cartridge still attached to the inner tube assembly of the fork?
I have seen a video that implies this is possible, if only fork seal replacement is required, and others that remove the screw that fastens the cartridge to the fork inner tube.
The video that left the cartridge attached used the inner tube as a slide hammer to pop the seal out of the outer tube.
 

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Are your seals leaking? Or you just decided to service the forks? From you questions I would advise you seek someone in you local area to service your front end. Cheaper and with a better outcome.

Good luck
 

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According to the service manual you are supposed to separate the inner and outer fork tubes before you remove the damper rod assembly; which I believe is the same as the cartridge. I'm no expert and can't keep up with the terminology of all the fork guts lol.

156825
 

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If the seals are leaking slightly it may just be caused by debris preventing a tight seal. You can buy or make a tool that will remove anything that may be causing the leak. I made one from a plastic soda bottle that worked great on a leaking seal on my bandit. I would try this before replacing what may still be a functioning seal.
 

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If the seals are leaking slightly it may just be caused by debris preventing a tight seal. You can buy or make a tool that will remove anything that may be causing the leak. I made one from a plastic soda bottle that worked great on a leaking seal on my bandit. I would try this before replacing what may still be a functioning seal.
My cheap version was the feeler gauges I had lying around :p.
 

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Discussion Starter #6
Thanks for the responses.

dcpppf you are correct about damper rod/cartridge and I should have looked in the manual.

1216bandit Yes I tried the seal mate , made one from a polypropylene icecream container. It worked the first time several years ago but the leak has returned and won't respond to the clean up.
 

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Discussion Starter #7
Are your seals leaking? Or you just decided to service the forks? From you questions I would advise you seek someone in you local area to service your front end. Cheaper and with a better outcome.

Good luck
1 is leaking.
I do all my own servicing and make any special tools necessary.
Getting someone else to do it,in my case, is unlikely to result in a better outcome
 

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Where I am luckly some local racer and ex race have a little shop. They do excellent work with fair prices, so I use them when I can. Plus my skill set is in the waning years. Agree, if one is leaking the other is soon to follow, good luck on the repair.

Ride sane.
 

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I'll have to replace the fork seals soon and I have a question about fork disassembly.
With the fork cap undone and the damper rod unscrewed from the cap, can the outer tube be withdrawn from the inner tube with the cartridge still attached to the inner tube assembly of the fork?
I have seen a video that implies this is possible, if only fork seal replacement is required, and others that remove the screw that fastens the cartridge to the fork inner tube.
The video that left the cartridge attached used the inner tube as a slide hammer to pop the seal out of the outer tube.
Buy a service manual or have a professional do it. Fork seals are a simple task and asking the internet is just plain lazy.
 

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1 is leaking.
I do all my own servicing and make any special tools necessary.
Getting someone else to do it,in my case, is unlikely to result in a better outcome
Unlikely to result in a better outcome? You don't know what you are doing. How could a great outcome come from that?
 

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I think he's asking if anyone has done what he's referring to. As for questioning his abilities, he can fabricate stuff that would amaze most of you, and has worked on his own bikes for 40 years.
If you have nothing of value to contribute, don't.
 

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Discussion Starter #12
I think he's asking if anyone has done what he's referring to. As for questioning his abilities, he can fabricate stuff that would amaze most of you, and has worked on his own bikes for 40 years.
If you have nothing of value to contribute, don't.
Saved me the trouble. Lol

Just completed making a seal driver in the lathe - in preparation.
 

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I'll have to replace the fork seals soon and I have a question about fork disassembly.
With the fork cap undone and the damper rod unscrewed from the cap, can the outer tube be withdrawn from the inner tube with the cartridge still attached to the inner tube assembly of the fork?
I have seen a video that implies this is possible, if only fork seal replacement is required, and others that remove the screw that fastens the cartridge to the fork inner tube.
The video that left the cartridge attached used the inner tube as a slide hammer to pop the seal out of the outer tube.
Yes.
 
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