Fork seals 101

A quick step by step guide showing how to change your fork seals. The forks in this video are from a Yamaha 1980 TT250 or TT500.

Category:

Autos & Vehicles

Tags:

• fork
• seal
• motorbike
• restoration
• restoation
• vintage
• classic
• vmx
• ahrma
• motorcycle
• mechanics
• rebuild

[wiredkiwi]

Hey Dave - the TT250 and XT250 forks are the same length and diameter as the TT500 forks but are not identical. The TT500 forks have a narrower tube section between the top and bottom clamps and are probably lighter. My last TT500 had TT250 forks on it and I would guess it is probably fairly common replacement for damaged originals.

[wiredkiwi]

Yeah it's not a smooth hole, it does have some flats or indentations so just keep trying. I had to reshape my broom stick a few times to get it to stick in there. If you can get hold of a rattle gun it might be easier than by hand too.

[jlpounds2001]

HI, could you tell me the diameter or the bar your using cause i got the classic allen bolt spinning the damper, it's on a 75 rd 350

Thanks

[wiredkiwi]

Hi - that's what the broom stick is for - you jam it into the end of the damper rod to stop it turning (up the open end of the fork tube) which is what the allen bolt screws into. It's a lot easier with an air wrench.

[gs400s]

2:15 At this point , do you put some loctite ( non-permanent ) on the allen screw ?? Or it's not a good idea ?? cause it's always diiffcult to remove ?

[wiredkiwi]

No I wouldn't do that, it's hard enough to get off as it is! Maybe a little oil and torque it up.

[rob1upon1gsxr1000]

I WANT YOU TO DO MY FORKS BRO.

[superbike352004]

Hi Mate,

Are those forks the same as a 1979 XT500??

Best Regards

Dave

[whoopdedolalala]

@jlpounds2001

you could use a broom stick, just push hard and gun the bolt

[edave5]

I hope this helps someone. I have an '83 YZ250 with 43mm KYB forks and had some trouble removing the hex bolt on the bottom of the fork.. If you are having trouble with the broom stick trick, use a nut with a width of 29mm (the one i got was a M20 - 2.5 nut), welded to a rod, or a piece of rebar. If you don't have a welder, get two of the nuts and jam them on a threaded rod. Essentially what you need to do is make (or buy if you can find one) a 29mm hex key.

[UvisionMedia]

Thank you for posting this. Wish the music was replaced with you explaining the steps though. If it wasn't for your comments I wouldn't have known that was a broom stick being used to hold the damper. Ok so now I have a question. Are there any bushings or other seals that I should inspect and possibly replace while doing this? Thank you for the video and the answers to all the questions.

[dirtyjett]

I'm afraid that I'll scratch my new fork tube which cost $280. I wish I had the guts, though.

[blueboxdude]

Just want to say thanks for the video.Pretty simple job when ya see it done like that.I just did my 82 yamaha maxim 750 forks and they are the same setup.Took me ten minues,6 to watch the video twice and 4 to do the work.Saved my self a couple hundred dollars.Thanx again

[herk650]

Folks, just don't get hit in the eye when those parts going flying out when using the screwdriver.

For pulling seals I prefer using a $10 seal puller form the auto parts store. Lever them out at the end of a work table w a scrap of wood to protect the tubes.

[brenthoser99]

awsome, so glad there is so much help on youtube for this topic. I am going my seals on a 78 kz650 soon and This is the type of thing that give a guy confidence. Hell I tear down and rebuild a small engine I can do this I think.