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Chea I need to get this done BAD! What would happen, if its dosnt get done right away. My left fork is leaking quite a bit.
 

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can we just redo this with pics that last longer than 90days? could you did a good job with what i can read
 

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Thanks for the how-to! once i pulled the forks off the bike it was pretty easy. I just thought that I would add that I was reluctant to mix "cheap" oil into the forks for whatever reason (i dunno im wierd about that i guess). Anyways, I compressed the fork without topping it off with the cheap oil and the seals popped out just fine. It makes alot of sense to do it with a fork full of oil, but for me it wasnt necessary.
 

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ski6 said:
Nice write up. As a side note, instead of using a screw driver to insert your new seal and possibly damaging it, make a seal driver. Buy some PVC the same diameter as your forks, cut it in half longways, clamp them together around your forks, and vwalla.
This seems really crafty! :thumbup But which type of clamp - a hose-clamp with the screw-set adjuster?
 

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Cesario said:
well done sir. i'm pretty sure it's the same thing with USD forks but it'd be nice to see a write up done with those so i know for sure.
Not sure If I will be doing this on my own for an '05 with inverted forks, but if so, I'll be sure to take pics with my crappy camera to share. I've got some more research to do on whether or not to have mine professionally re-valved and re-sprung for my weight.

Anyone have suggestions on suspension specialists??
 

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Jakeroo7 said:
This seems really crafty! :thumbup But which type of clamp - a hose-clamp with the screw-set adjuster?
That works or I just taped mine real quick pounded in the seal then pulled the tape off and did the other fork. Just make sure the pvc is long enough to get a good hit in...atleast 6 inches.

I don't know if this how to would work on usd forks.
 

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Eat Your Boogers
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Could i follow the same steps for the seals on an 03? Or are there differences?
 

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Eat Your Boogers
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Alright. just checking cause right fork keeps getting worse, so im going to need to do this soon
 

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Zar said:
Could i follow the same steps for the seals on an 03? Or are there differences?
'03 forks are still right-side-up. I have inverted forks, so things will be different for me. '03 should be almost identical to 99-02 in set-up.
 

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so i got my fork seals to pop but cant seem to get it all the way out anyone ever use the just pull apart way that is what i have been to do buy so buddies anyone know if it will work
 

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just as an FYI, you don't need to top off the fork w/ oil and compress it to get the old seal out. just slide hammer the 2 tubes out once the dust cover and clip are removed.

also try to use the same viscosity and brand you were using or planning on using, not car oil.
 

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Mine need doing this weekend, So its been a good read. What about the air gap people talk about? Or is that the same as the amount of oil that goes in?.

Luke
 

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Alright lots of back and forth on this and for the life of me cannot understand why there is no video for the 1st gen out there. Buttt my question pertains to parts 11-12 seen in the 1st image. Looks like the rubber with the 4 ridges faces up. (I have the shop many too) does not specifically mention the orientation of this part) it appears to go under the forks inner tube to provide cushion in the event of a bottom out? Normally I'm very careful with paying attention to my disassembly of parts in their orientation. However when I disassemble the first fork with the slide hammer method, this part fell to the floor, and admittedly I pulled the rubber off right away to clean the whole thing. After looking at the photo of the dissected view, I inserted it as shown with The ridges facing up. To check I disassembled the second fork. Making sure to pay extra close attention to the way the rubber was facing. On my second fork the rubber ridges face down... Practical thinking tells me to follow the manual and the dissected view image. However... When, the ridges face up in the fork, the bottom of part 11 is free to hit the bottom of my fork tub housing :/ when it's reversed the flat side up ridges down, the ridges go down past the bass providing a buffer between the inner tube and outer tubs... Want to make sure I get this right before I go through the hassle of changing anything.
57404
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see mettle bass exposed...
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way it came out of the 2nd fork...
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in this orientation as seen above keeps the mettle cylinder's bottom from being exposed when put back into the tubes.
57409
 

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57410

I believe this is how it appears on the schematic.. rubber ridges up however if you can imagine the wooden stool being the bottom of the inner fork tube the metal wood hit metal? And this is how it came out of my tube with ridges down.
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