I have notice there isn't a true write up for changing your fork seals. So here it is. I have pieced this write up through extensive research throughout the web and through this site. By no means I call this my own original work. I hope this helps a few of us that doesn't have the money to buy all the true accessories, so I use typical hardware available in any hardware store. Also I am sorry for the low resolution of the pic because I do not own a digital camera. These pics are from my iphone. Again sorry.
- 14mm open wrench
- 22mm socket w/ handle
- large hex wrench in the tool case (provided with bike)
- 8 inch adjustable wrench
- dull flat head screw driver
- hack saw or dremel with cut off wheel and sander
- a friend that is strong
- X2 3" bolts full threaded or longer w/ nuts
- X2 3/4" stainless steel screws w/ x4 washers and x4 nuts
- X2 90 degree bars with holes (whichever length is good enough)
Tools to make:
- 1.25" pvc seal driver
- spring compressor
- leaky fork
- brand new fork seals (oem or other source)
- nitrile gloves, atleast 2 pairs
- microfiber towel
- disposable towels
This is some of the tools you would need!
1. Tools to make
Buy 2 1.25" pvc couplings and some epoxy glue from Home Depot. Go home and glue the two pieces together and wait until dry. When fully dry, cut in half and sand down the rough edges. You can also use a left over pvc if you have some lying around but most places require you to buy the whole 8' pole. Once you are done this is your driver.
Next take your two 90 degree bars and the 3/4" screws with washers and nuts. If you assemble it, the washers should go on both sides of the middle of the bar. Here is a pic of how it should look like.
Now set these aside until later.
2. Removal of the fork
Next step would be to remove the fork off of the bike. FIRST turn all the dials to SOFT! Take the flat head and turn the top counter-wise until you can't turn no more. This is the same as the bottom near the axle. Finally use your 22mm socket and turn the black dial counter-clock wise as well. Now to remove the for there are several ways to do this. One way is to have the bike resting on some car jacks. If you have a triple tree stand that is even better. Before you take it off the top clamp loosen the top nut using the large hex wrench provide with the bike.
3. Removing fork
Now that you removed the fork off the triple tree, unscrew the top cap and slide down the gold barrel to reveal the cartridge. You will notice that there are two holes on either end of the white pvc. That is where we will assemble the spring compressor. It is assembled by using the 3" bolts with the nuts. This is better if your friend is holding up the fork while you assemble it. This is a pic of how it is assembled:
4. Compressing the spring
This one of the tricky parts. You want to have your friend push down on the bar while you loosen the cap. It is not as easy as it seems. The spring is very stiff and requires alot of balance and downward force to reveal the nut. Here is a pic without the spring. You want to use your adjustable wrench and 14mm open wrench for this. Also be sure to have a rag on the bottom of the fork so you don't scratch up the bottom.
Once it is off you can loosen the cap revealing the dampening rod. Now drain the fork oil in to a container. Inverting the fork over the container pump the dampener holding the nut until all the oil is out. Use a towel to wipe the used oil off.