2006 fork service?

2 replies to this topic
  • dugbud

Posted May 20, 2006 - 07:01 PM


Can someone help me out? I need to change the seals on my forks but, I don't know where to start? I've changed seals on my 04 regularly but the 06 fork is different. Please help

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  • SX4ME

Posted May 20, 2006 - 08:53 PM


As posted by Shawn Mc.
Any questions, holler his way!!!
Re: Blown Fork Seal
Heres the quicky procedure:
Assuming the fork is off the bike...

Unscrew the large cap, dump the oil. screw the cap back on.
Loosen up the rebound adjuster nut. Holding the fork somehow (how is up to you) push the fork together and the damper rod will poke out the bottom. Snag that sucker with a 12-14mm wrench. At this point, take the rebound adjuster nut gismo off the damper rod. Its just screwed on the end and jammed there with the jam nut that has two flats ground on it (17mm). Once the rebound adjuster is removed, squeeze the fork again, take the wrench off the damper rod and re-unscrew the big cap and pull the entire damper out of the fork. Pick the spring up off the floor and wipe up the oil you just spilled too...knuckle head...

Now, to replace the seals. Use a small screw driver or a paint scraper or something really thin to pry up the dust cover on the seal. Dig the retaining clip out with a small screw driver and a pair of needle nose pliers. Once you get the clip out, you simply slide hammer the fork apart. Bang bang bang..its a part...wipe up the oil you just spilled...man your making a huge mess...pay attention to what your doing ok...jeese...

A smart guy would change the oil in the damper too. Its easy enough. Just unscrew the center of the top of the damper (compression clicker) and then to remove that assembly slowly compress the damper rod. Compressing the damper rod will reduce the vacuum that is pulled when your trying to pull the "compression bolt" out. Once its out, just dump the oil...stroke the rod...to aid remove of fluid...get your mind out of the gutter...

Reassembly is reverse everything, assuming you understand how to install the new seals. Use a baggie or something like a baggie over the end of the fork tube when you slide the new seals on to prevent damaging the tiny edge that does all the sealing work...sux when you gotta do it again because you didn't practice safe seal...

Stock oil height in the outside chamber is 412cc. Put 200 in the inner chamber. Some will burp out of the inner chamber. Make sure you pour that off/out the holes in the inner damper.
If you do both chambers in both forks you'll need roughly a quart and a half of fork oil (I use Synthetic ATF)

Anything else?

  • DaveJ

Posted May 21, 2006 - 11:52 AM


Can someone help me out? I need to change the seals on my forks but, I don't know where to start? I've changed seals on my 04 regularly but the 06 fork is different. Please help

It's not that different. If you need help with it, PM me and I'll walk you through it. If you're local you can bring it by and we'll change 'em on the spot. :ride:

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