Awesome video, a good idea is to put tape or a plastic bag over the top of the stanchion, when sliding the oil seal on. Sometimes the stanchion can have sharp edges. Also I put the old oil seal on top of the new one, so when you drive it home it protects the new one 👍
Just changed my forkseals. They didnt pop at 110 psi. so i heated up the outside a little bit and pumped it up to 70 psi and came out very easily. Thx for the good video it saved my butt.
The assholes at the local shop here tried to charge me 180 bucks to do this. I said no way and did it myself with this video in 40 min... thanks man! you saved me load of time and cash!
180 bucks is a reasonable charge for the amount of labor and skill to to this job properly. Perhaps if the "assholes" quoted you $500 or more yeah, but less than 200? Not bad to remove, dissemble, inspect and clean front forks.. not bad at all.
Thanks for the video. I replaced the springs a while back, but you had some great pointers for doing the seals. A bike pump will pop the old seals out, but I had to pump up to 100 lbs...
Came back to this video after 3 years, replacing seals again (go with OEM kawasaki seals, not all balls), and super grateful. Was able to get this done in my AirBnB host’s driveway on a tarp with a mini 12v portable air compressor from Harbor Freight. I ended up putting 100 psi into one of the forks before it blew, so definitely a good air compressor is needed in case that happens. I also wonder if you could screw into the seals with a few small screws and yank them that way. Thankfully didn’t need to try.
If fork seals aren't coming out with 50+ psi, use a heat gun or hair dryer. Mine weren't coming out at 100psi, but after a couple minutes with the hair dryer they popped at around 60psi
I love it. watch the video read the comments change the fork seals that easy. I used a little air pump pop them right out. used inch and a half PVC and the old fork seal to press the new ones in. filled the forks with ATF fluid easy peasy
Thank you! I just did it. I have normal fork caps but on the bottom of the fork there is that litle screw to get rid of old oil. I just warm up the fork seal and press air gun (with normal small nozzle to blowing dust) to that little hole and the fork seal pop out:) Be careful couse "the little hole" got a little seal and its easy to blow away when the pressure is escaping from fork if the fork seal didn't pop out for the first time. I use a towel to cover up air gun, aspecially around the nozzle to stop escaping little seal. I hope you'll understand me:D
You may want to add that while reattaching the speedo to the wheel, you need to make sure the washer nubs are lined up both with the wheel and the speedo assembly. If your speedometer doesn't work after putting everything back together, this is probably the culprit. KLR veterans know this, but the newer folks usually don't...
Also make sure the speedo assy is well greased... klr owners who put their bikes through hell (dirt, mud, water, dust....etc) need to do this in order to have the unit last and not break the hub tabs.... that will save you from buying a front wheel/hub
I did this trick with my Yamaha XS1100 shocks-after draining oil/air I'd just slide the lower reservoir section off the upper fork without taking it off the tree. It gave handy access to the seals-I'm just not sure if the KLR is similar because it saved me lots of time and work.
Thanks for the video. Your link to Roostchucker’s video is a must. Big help with my fork seal replacement. I couldn’t get the seal to pop out with the fork tube on my bench like you show, even when pressurizing the fork tube to 100psi+. Watched Roostchucker’s video where he placed the fork tube vertical on the floor when pressurizing it with air. Pressing downward when airing the fork tube did the trick. Seal and dust cover popped right out.
I used this method for my KLR 650 awhile back. Thanks for great idea that saved me some time. I am now wondering if I can get this idea to work on my 2002 Kawasaki Concours ZG1000. I am sure I will find out. I just order the fork seals, new tire, bearings, front brake pads, and prepping for a cycle of my front end maintenance. Doing all my own wrenching to keep my bikes dependable, and purring like kittens.
A tip, loosen the fork caps before you remove forks off the bike.. just break them free and no fluid will be lost.. I drain oil with forks off. But I like the compressed air trick. I might have to try that
Came here to say that. Loosen the top triple clamp pinch bolts, then loosen the fork tube caps. THEN, remove the forks, complete the seal job, refill with oil, and reinstall, finally retightening the caps and top triple clamp bolts.
Great video. This is a pretty easy job and I am in no way a mechanic.myOnly issue was that my seal was bad so when I pumped air into it it just leaked out and never popped the seal out. I just used a small pin and hooked it out. Slid right out.
That’ll happen if you let the seals get too bad before addressing it. Helps if you have a BIG compressor. Enough air flow will overcome a small leak. Kinda like seating a bead on a tubeless tire.
Do you remember what was the height of the fork seal? There are many types available on the market. Some of them are 9.5mm some of them are 10,5mm. I have no idea which of them are the correct ones for the model like yours. My bike is from 2004 but most probably the forks are identical.
+Tevorek Motovlogs I'm so sorry! It is actually 1 1/2 inch pvc. I measured the outer diameter instead of the inner. Thanks for pointing that out. I'll fix it in the video today. Sorry about the mistake.
+Tevorek Motovlogs If you use the black 1.5in pvc, it is almost exactly the size of the seal. Just slightly smaller. It should fit inside of the fork slider.
If I were to upgrade my springs during this job, what further disassembly is required? Would the upper tube just slide out of the lower tube once the seals are removed? Great video, thanks in advance!
YOU YOU NEVER SAID WHATS THE NUMBER OIL YOU USED AND ALSO WHAT AMOUNT 100CMS OR 300cms MORE OR LESS THAT AMOUNT DID YOU PUT INSIDE IN EACH BAR THANKS A LOT I HOPE YOUR ANSWER AND GOOD JOB
Nice video, that is a really clever way to pop the fork seals out of the tube I have never seen that before using the air pressure....... have you ever done fork spring replacement?
I haven't. My klr came with progressive fork springs. But they are very easy to install. Just drop them in through the fork caps. You also have to cut your spacers in half.
nice, thank you... have you heard of this clutch kit? Magnum MX-Pro Clutch Kit... I have not but my clutch is bad.. or the springs but i figure i will just do the whole clutch set... thank you again..
+kcatto21 Never heard of them. I can't find much on the internet about them either. If you decide to give them a try, let me know what you think. You may want to ask around the KLR forums. Someone there has likely used them and can tell you if they are good or not.
Curious about that myself, as raising the fork stanchions in the triple tree makes the steering angle steeper, which makes steering quicker/twitchy, and LESS stable.
Hey all, I'm a measly mechanic and want to do this job. I am limited on tools and will need to buy more, but could anyone tell me what size the fork cap but is? Thanks in advance!
HI, is true about the need to purge the air bubbles on the oil when you put on the fork ? I read is neccesary simulate the fork suspension just to permit exit the air on the oil after of that you can close the fork. thank for you opinion
HOW MUCH AMOUNT DO YOU PUT LIQUID EACH BAR I'am DOING MAINTENANCE MY KLR MAYBE I HAVE TO DO CHANGE THE ORINS OIL SEND ME HOW MUCH IAM WRITING FROM MÉXICO MY CITY ITS COAHUILA STATE PARRAS DE LA FUENTE COAHUILA COME HERE TO ENJOY GOOD LIFE I HAVE OTHER HOUSE WILL YOU DONT NEED A HOTEL COME ON MAN
Dice mi manual de mantenimiento 355cc (12oz) de aceite. Puede meter el tubo interior completamente y medir del canto del tubo interior hasta el aceite. Debe medir entre 188-192mm (7.4-7.56 pulgadas). Bendiciones del Ejido Parras.
Awesome video, a good idea is to put tape or a plastic bag over the top of the stanchion, when sliding the oil seal on. Sometimes the stanchion can have sharp edges. Also I put the old oil seal on top of the new one, so when you drive it home it protects the new one 👍
Oh man wish I had read this a couple hours ago!! Great idea
Just changed my forkseals. They didnt pop at 110 psi. so i heated up the outside a little bit and pumped it up to 70 psi and came out very easily. Thx for the good video it saved my butt.
Thanks! Experienced the same thing. Hadn't thought of heating the tubes up. Worked like a charm!! Cheers!
Thank you so much! I had the same issue, heated them up and they popped no problem.
Best video for setting new fork seals. Air compressor to remove the seals. 1 1/2” PVC to set the seals.
I discovered that it wasn't 2" too.
The assholes at the local shop here tried to charge me 180 bucks to do this. I said no way and did it myself with this video in 40 min... thanks man! you saved me load of time and cash!
No problem. Just be aware, as other commenters have pointed out, you don't get to clean it the forks with this method.
180 bucks is a reasonable charge for the amount of labor and skill to to this job properly. Perhaps if the "assholes" quoted you $500 or more yeah, but less than 200? Not bad to remove, dissemble, inspect and clean front forks.. not bad at all.
Thanks Bro. worked out just as you described. Saved myself $400 Canadian (300 Us). That's with me removing and reinstalling the forks! Regards, Nick
I'm so glad I could help! Thanks for watching!
great explanation of how everything is done and what not.
Thanks for the video. I replaced the springs a while back, but you had some great pointers for doing the seals. A bike pump will pop the old seals out, but I had to pump up to 100 lbs...
Came back to this video after 3 years, replacing seals again (go with OEM kawasaki seals, not all balls), and super grateful. Was able to get this done in my AirBnB host’s driveway on a tarp with a mini 12v portable air compressor from Harbor Freight.
I ended up putting 100 psi into one of the forks before it blew, so definitely a good air compressor is needed in case that happens. I also wonder if you could screw into the seals with a few small screws and yank them that way. Thankfully didn’t need to try.
If fork seals aren't coming out with 50+ psi, use a heat gun or hair dryer. Mine weren't coming out at 100psi, but after a couple minutes with the hair dryer they popped at around 60psi
I love it. watch the video read the comments change the fork seals that easy. I used a little air pump pop them right out. used inch and a half PVC and the old fork seal to press the new ones in. filled the forks with ATF fluid easy peasy
Thank you! I just did it. I have normal fork caps but on the bottom of the fork there is that litle screw to get rid of old oil. I just warm up the fork seal and press air gun (with normal small nozzle to blowing dust) to that little hole and the fork seal pop out:) Be careful couse "the little hole" got a little seal and its easy to blow away when the pressure is escaping from fork if the fork seal didn't pop out for the first time. I use a towel to cover up air gun, aspecially around the nozzle to stop escaping little seal.
I hope you'll understand me:D
You may want to add that while reattaching the speedo to the wheel, you need to make sure the washer nubs are lined up both with the wheel and the speedo assembly. If your speedometer doesn't work after putting everything back together, this is probably the culprit. KLR veterans know this, but the newer folks usually don't...
Thanks for the tip! I think it went back together fine, everything is working. I'll go double check it just to be sure.
Also make sure the speedo assy is well greased... klr owners who put their bikes through hell (dirt, mud, water, dust....etc) need to do this in order to have the unit last and not break the hub tabs.... that will save you from buying a front wheel/hub
I did this trick with my Yamaha XS1100 shocks-after draining oil/air I'd just slide the lower reservoir section off the upper fork without taking it off the tree. It gave handy access to the seals-I'm just not sure if the KLR is similar because it saved me lots of time and work.
Clear and concise directions, thank you! I also have a green one.
Thanks for the video. Your link to Roostchucker’s video is a must. Big help with my fork seal replacement. I couldn’t get the seal to pop out with the fork tube on my bench like you show, even when pressurizing the fork tube to 100psi+. Watched Roostchucker’s video where he placed the fork tube vertical on the floor when pressurizing it with air. Pressing downward when airing the fork tube did the trick. Seal and dust cover popped right out.
Made the seal replacement super easy. Thanks!
Brilliant idea with the air
Definitely helpful! Thank you!
KLR is so clean lol....has it ever been offroad?
I used this method for my KLR 650 awhile back. Thanks for great idea that saved me some time. I am now wondering if I can get this idea to work on my 2002 Kawasaki Concours ZG1000. I am sure I will find out. I just order the fork seals, new tire, bearings, front brake pads, and prepping for a cycle of my front end maintenance. Doing all my own wrenching to keep my bikes dependable, and purring like kittens.
Thank you! Mine was leaking like CRAZY (no fluid left) and still took 120PSI to blow the seals out
A tip, loosen the fork caps before you remove forks off the bike.. just break them free and no fluid will be lost.. I drain oil with forks off. But I like the compressed air trick. I might have to try that
It's really pretty fun when they pop!
Came here to say that. Loosen the top triple clamp pinch bolts, then loosen the fork tube caps. THEN, remove the forks, complete the seal job, refill with oil, and reinstall, finally retightening the caps and top triple clamp bolts.
Do you think this method would work with fork seals that leak more severely than yours did? Would the air compressor still pop them out?
Video says to use 2” PVC but it’s 1.5”
I am glad I read this comment, but I am not glad I read it after buying 2” pvc
Is that 1.5" ID or OD?
@@PanaLumberjack Don't remember sorry
I thought so!!! I went looking for this comment to confirm it was 1 1/2 inch PVC
Clear commentary, very helpful thanks
do you need an air compressor to pop those seals loose? I don't own one and don't feel like buying one right now.
Just what I needed. Thanks.
Man your bike looks great!
Mine is the same color way
Great video. This is a pretty easy job and I am in no way a mechanic.myOnly issue was that my seal was bad so when I pumped air into it it just leaked out and never popped the seal out. I just used a small pin and hooked it out. Slid right out.
That’ll happen if you let the seals get too bad before addressing it.
Helps if you have a BIG compressor. Enough air flow will overcome a small leak. Kinda like seating a bead on a tubeless tire.
HE HOW MANY MIMILIMETERS DID YOU FILL OIL EACH BAR SUSPENSIÓN
great video! thank you for putting this info together.
+Chip McKenzie thanks for watching!
thank you
Do you remember what was the height of the fork seal? There are many types available on the market. Some of them are 9.5mm some of them are 10,5mm. I have no idea which of them are the correct ones for the model like yours. My bike is from 2004 but most probably the forks are identical.
can't figure out which way to put the seal and dust seal on? i got those amazon ariete seals...helppppp
Missed it how you got the old calls out with pressure. Do I need special tool
it is the same valve as a car tire, you can find pieces to connect a compressor to the valve at any store where they sell compressors
I went and bought a 2 inch pvc pipe and it was the same diameter as the fork, so I couldn't hit the seal back in. What did I do wrong?
+Tevorek Motovlogs I'm so sorry! It is actually 1 1/2 inch pvc. I measured the outer diameter instead of the inner. Thanks for pointing that out. I'll fix it in the video today. Sorry about the mistake.
+Obsessive Cycle Disorder no problem! Thanks! When you put the tube over the dust cover did it go over the part on the fork, or on the top of it?
+Tevorek Motovlogs If you use the black 1.5in pvc, it is almost exactly the size of the seal. Just slightly smaller. It should fit inside of the fork slider.
If you don't have the tools or an A/C garage... it'll take you a week. Hence the reason I haven't started it LOL
If I were to upgrade my springs during this job, what further disassembly is required? Would the upper tube just slide out of the lower tube once the seals are removed? Great video, thanks in advance!
+Michael Whittaker it is a very easy upgrade. They just drop right in from the top. No further disassembly required. Thanks for watching!
Does the fork brace give any advantage?
can cruise at higher speeds if you have 50/50 tires on and not get speed wobbles
YOU YOU NEVER SAID WHATS THE NUMBER OIL YOU USED AND ALSO WHAT AMOUNT 100CMS OR 300cms MORE OR LESS THAT AMOUNT DID YOU PUT INSIDE IN EACH BAR THANKS A LOT I HOPE YOUR ANSWER AND GOOD JOB
Nice video, that is a really clever way to pop the fork seals out of the tube I have never seen that before using the air pressure....... have you ever done fork spring replacement?
I haven't. My klr came with progressive fork springs. But they are very easy to install. Just drop them in through the fork caps. You also have to cut your spacers in half.
nice, thank you... have you heard of this clutch kit? Magnum MX-Pro Clutch Kit... I have not but my clutch is bad.. or the springs but i figure i will just do the whole clutch set... thank you again..
+kcatto21 Never heard of them. I can't find much on the internet about them either. If you decide to give them a try, let me know what you think. You may want to ask around the KLR forums. Someone there has likely used them and can tell you if they are good or not.
Good video thanks for making this
Awesome, thanks! What weight fork oil do you use?
+Tevorek Motovlogs It is Bell-ray 10 weight. Thanks for watching!
would a car tire pump work? The ones you plug into a lighter socket, or are they not powerful enough?
+Hehanni if should work, it will just take longer. Thanks for watching!
Did the front fork work cure the handling issues?
+jsandidge1 It did! Handles great now. I can comfortably to 60mph on gravel now. Thanks for watching!
Curious about that myself, as raising the fork stanchions in the triple tree makes the steering angle steeper, which makes steering quicker/twitchy, and LESS stable.
Fork seal how do I know what face is looking at what side
здравствуйте)в klr650A сколько нужно масло лить?350 мл?
What happened to the KLR'S and the Tengai builds?
KLR builds are on their way back! I just finished a new fairing for the KLR and I will be doing a video about it soon. Tengai to follow...
Siiicckkkk got stuff
Hey all, I'm a measly mechanic and want to do this job. I am limited on tools and will need to buy more, but could anyone tell me what size the fork cap but is? Thanks in advance!
19MM on my 1985 KLR250. don't know if they have changed the specs.
HI, is true about the need to purge the air bubbles on the oil when you put on the fork ? I read is neccesary simulate the fork suspension just to permit exit the air on the oil after of that you can close the fork.
thank for you opinion
+enzo ottaviani I have heard that too, but I haven't had any trouble...yet.
My forks do not have a Schrader valve..
What about presta lol
This is Gen 1, very old school. 7:03
That is way too clean to be a KLR.
HOW MUCH AMOUNT DO YOU PUT LIQUID EACH BAR I'am DOING MAINTENANCE MY KLR MAYBE I HAVE TO DO CHANGE THE ORINS OIL SEND ME HOW MUCH IAM WRITING FROM MÉXICO MY CITY ITS COAHUILA STATE PARRAS DE LA FUENTE COAHUILA COME HERE TO ENJOY GOOD LIFE I HAVE OTHER HOUSE WILL YOU DONT NEED A HOTEL COME ON MAN
Dice mi manual de mantenimiento 355cc (12oz) de aceite. Puede meter el tubo interior completamente y medir del canto del tubo interior hasta el aceite. Debe medir entre 188-192mm (7.4-7.56 pulgadas).
Bendiciones del Ejido Parras.
También aquí hay más
ruclips.net/video/25EC60C7jlM/видео.html
Stop shouting brooooo, escribir en mayúsculas es gritar en EEUU hombre