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Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
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  #1  
Old 7 May 2008
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Fork Seal Replacement!

I'm going to be riding my motorcycle 1200 miles, halfway across the country in two weeks, and I need to replace my fork seals.

What special tools do I need? And are there any good ways to improvise those tools?

Thanks,
-Micah
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Old 7 May 2008
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What bike is it?

Regards

Nigel in NZ
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Old 7 May 2008
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Sorry - It's a 1990 XT600E.
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Old 8 May 2008
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fork seals

hello that is an interesting question because i am just trying to do my fork seals as well. i have taken my forks off the bike and i dug out one seal which was very corroded with a screwdriver to find a clip holding another seal in place so i took the clip out but cant get at the seal it is too deep in the housing so i have undone the bolt in the bottom thinking it would all come apart so i could get to the seal but it doesnt seem to,also when i took the top caps off one was ok and the other spring popped out like a jack in a box should it do this ?? any info would be very helpful thank you
:confused1s my forks seem to be from an 1987 1vj.

Last edited by wrussell; 8 May 2008 at 23:21. Reason: to add model
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Old 9 May 2008
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Yeah, they're supposed to fly out like a coiled viper, just have to be careful when you do that.

Apparently you take off the top cap, remove the fork spring, then dump out the oil. At which point you take off the snap ring holding the seal in. Then you take off the bottom bolt and you can use some sort of tool (?) to run down the inner tube and another (?) into the bolt hole. That will loosen the damper rod bolt so you can yank the inner tube out.

The part I don't get is what the special Yamaha-issue tools are, or what I could improvise.
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Old 9 May 2008
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That information came from the XT600E service manual that Kentfallen kindly posted, to give credit.
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