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Fork seals

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Can someone tell me what is involved in changing the fork seals on an 00 KX80? I am fairly good mechanically but have never had to change the fork seal ( or service forks always paid to have it done!) before. Thanks I would appreciate any assistance you can give! Thanks again

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I had an older fork (1991). The bolt that holds the top tube/valving to the lower tube unscrews from the bottom of lower tube. Inside is the head/nut that has a hex shape taper. If everything is clean and not cross-threaded, you can take apart easy without any special tools. If needed used a rubber cork and wedged in to stop it from turning and remove the bolt. Afterwards I made a mating tool so I could reassemble the fork otherwise you will not be able to tighten it.

Fork comes apart in the seal area the same as others. Dust seals/wipers, ring clip, seal, washer, bearing,,,, You may not need to take apart the fork if you use a screw to rip the seal out. Just dont cratch the tube.

Edited by weantright

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it's very simple but the tricky part is having the correct tools. Mainly the seal driver and most importantly, the service manual. The manual will tell you step-by-step and give you all the specs. As for the driver, talk to some local folks, they may have one you could borrow. I think they are 38mm. Can't remember.

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Seal drivers are for the shops. You can use PVP pipe, old seal or just push in. I have done alot of forks and never had a problem pushing in seals. Now getting the seal over the threaded top tube, seal bullet would be nice.

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Bullets are like $5 or something at Motosport. You can use tape, plastic bag or an old rubber. :ride: You'll need to lube the tape and the plastic bag though.

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sooner or later i am replacing my 97 kx100 fork seals but what i am stuck on is rebuilding the top end i am trying to find top end gasket kit and rings so far i found a gasket kit for 28.85 and 27.99 i am trying to find rings but not having that much luck

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I just throw some duct tape over the top and make sure it covers the indented ring where the top bushing sits as well. Throw a little grease on them, and on they go. Use PVC pipe, unless your doing them all the time the driver isnt worth it to me anyways.

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Seal drivers are for the shops. You can use PVP pipe, old seal or just push in. I have done alot of forks and never had a problem pushing in seals. Now getting the seal over the threaded top tube, seal bullet would be nice.

i disagree, nothing beats a real seal driver, although yes its possible without one. but i have a lathe and make my own.

P5020004.jpg

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For anyone who says a real seal driver is not needed, you really should actually try one. I think you will find it is so much better.

Great job on the seal driver, hi_im_sean!

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