Join Date: Sep 2018
Location: Central Indiana
Motorcycle: 2018 Suzuki GSX-R 750, 2003 Kawasaki ZX-9R, 2001 Kawasaki ZX-6R & KX250 Motarded
I have done many fork seals and removing them from the bike is really the hardest part.
My suggestions and tips:
1. Make note of your current settings. Back all of the adjustments off. This includes compression, rebound, and spring preload. This will relieve some spring pressure and make it easier to purge air out of the oil later.
2. Loosen the fork cap using a six-point socket (12-point will cause more damage to the hex finish) before loosening the pinch bolts on the triple tree. It is a large hex so you can always rent one from the local auto parts store.
3. The cartridge is held in the lower fork tube with a socket head Allen. The manual will tell you to use a special cartridge retaining tool. You can get around this by using an impact and shocking it. If you keep the trigger pulled, the cartridge will just spin with the allen. But it you press/release several times it will spin out no problem. Do the same when tightening until it is snug, then put a torque wrench on it.
The problem with the above mentioned allen, is that it is deep in a counterbore above the axle. Since you are using an impact, you'll need an allen that extends several inches beyond the socket as a 3/8" drive socket will not fit in the counterbore. Pull that allen out of the 3/8" drive socket, find a 1/4" drive 6-point socket the same size as the allen and use that with an adapter.
4. Buy a quality seal driver or borrow one from a buddy. They are made of brass and have enough weight to drive the seal.