Suspension Replacing KYB Fork Seals

[jackson409]

Step 1: Loosen only the top triple clamps on your bike, then break top fork cap nut loose. Don't remove the cap, just break it loose. It will make it easier to remove once the forks are off the bike.

Step 2: Remove the forks from the bike.

Step 3: Back out the compression and rebound adjusters all the way out.


Step 4: use a flat tip screw driver and carefully remove the wiper from the fork and slide it all the way down.



Step 5: Using a pick or small flat tip screw driver remove retainer clip.



Step 6: Remove the fork cap



Step 7: Pour out the oil.



Step 8: Pull down the spring and slide a wrench on the spanner nut and break it loose and remove the cap from the damper rod assembly.



Step 9: Remove the spring and damper center rod.



Step 10: Work the damper assembly up and down, pumping oil out of the center assembly. Pour out the oil and repeat several times until the damper assembly pumps dry. You will tell when it is empty. It will very easy to work up and down and you will hear it sucking air.





Step 11: Pull the outer fork housing off the fork tube. It takes alittle force separate them.

Step 12: Remove the Inner bushing, outer bushing, washer, oil seal, retainer clip and finally the wiper.













Pay attention to how these come off they will need to go back on in the same order. Now that you have it apart inspect your bushings and clean all of your parts and fork tubes.

 

[jackson409]

Special Tools needed: Seal Driver, seal bullet, fork oil level tool
*** you can get by without these tools but will need to manufacture you own tools. (I'll Explain this later in the thread)

Step 1: Use your seal bullet to cover the end of the fork tube. Those edges are very Sharp and will cut your wiper and oil seal. *** I used black electrical tape.





Step 2: Apply some oil to the inside of the wiper and slide carefully over the seal bullet or tape in my case.





Step 3: install the retainer clip.



Step 4: Apply some oil to the inside of the oil seal and slide over the bullet again tape in my case.



Step 5: Remove the seal bullet or tape and install the washer, outer bushing and inner bushing.





Step 6: Use your seal driver to drive in the outer bushing in then use the driver to drive in the oil seal. Sorry couldn't get pics of this. I used this rubber boot and a hose clamp to hold it onto the fork tube and used the slide action of the outer fork tube to install the bushing and oil seal. You can also use a 4'' long peace of 2'' PVC pipe cut in have to wrapped around the fork and use a hose clamp to hold around the fork.



Step 7: Install the retainer clip and push the wiper on with hand (no driver needed for wiper)

Step 8: Collapse the fork all way down and fill to the top with oil. Work the damper assembly up and down several times pumping the oil into the assembly. You will have to keep adding oil You will know its full when the oil level stops decreasing.



Step 8: You will need to look in your manual to determine the oil level specific to each manufacture. My oil level for my bike is 100mm with no spring and damper all the way down. Set your oil level tool to the amount specified in you manual and remove oil until it starts sucking air. *** I used a piece of fuel line hose measure about 2'' inches longer than 100mm. I then wrapped some electrical tape at 100mm and set a washer up to the tape and then inserted the hose down to the washer touched the fork. I then used a turkey baster to remove the oil down to 100mm below the top of the fork.



Step 9: Install the damper center rod and spring.



Step 10: Install the cap back onto the damper Assembly then install back into the tube.



Now you can set you rebound and compression adjusters back to factory setting or where you had them at before. Install the forks back into your bike and tighten the bottom clamps first then tighten down the fork caps. Now you can finish the rest. Ride and enjoy