Changing fork seals the easy way !
description
Transcript of Changing fork seals the easy way !
![Page 1: Changing fork seals the easy way !](https://reader036.fdocuments.in/reader036/viewer/2022062518/56814224550346895dae398a/html5/thumbnails/1.jpg)
Changing fork seals the easy way !
Using the ‘SMITHY’ patent hydraulic fork seal press.
![Page 2: Changing fork seals the easy way !](https://reader036.fdocuments.in/reader036/viewer/2022062518/56814224550346895dae398a/html5/thumbnails/2.jpg)
Health and Safety
• The procedures depicted here have been performed by a professional Engineer.
• Please do not attempt any of these operations unless you have been deemed to be a competent person.
• Wear the correct PPE, adhere to appropriate Health and Safety guidelines and dispose of any wastes created in accordance with local regulations.
![Page 3: Changing fork seals the easy way !](https://reader036.fdocuments.in/reader036/viewer/2022062518/56814224550346895dae398a/html5/thumbnails/3.jpg)
Remove the fork oil drain screw using the correct tool for the fastener type.
![Page 4: Changing fork seals the easy way !](https://reader036.fdocuments.in/reader036/viewer/2022062518/56814224550346895dae398a/html5/thumbnails/4.jpg)
Drain the stinking,
contaminated and probably carcinogenic
oil into a convenient receptacle.
![Page 5: Changing fork seals the easy way !](https://reader036.fdocuments.in/reader036/viewer/2022062518/56814224550346895dae398a/html5/thumbnails/5.jpg)
• The owner of the 1984 YZ125 forks forgot to loosen the top nut before removing them from the bike.
• I had to make a 43mm hole in a piece of softwood using a hole saw.
• A slit was cut from the edge to the hole to allow the wood to grip the slippery chrome plated fork inner.
![Page 6: Changing fork seals the easy way !](https://reader036.fdocuments.in/reader036/viewer/2022062518/56814224550346895dae398a/html5/thumbnails/6.jpg)
![Page 7: Changing fork seals the easy way !](https://reader036.fdocuments.in/reader036/viewer/2022062518/56814224550346895dae398a/html5/thumbnails/7.jpg)
With the fork inserted into the
wooden fixture and clamped in the
vice, the top nut can be removed.
A hexagonal socket was used rather than a bi-hex as
they are kinder to the alloy nut.
![Page 8: Changing fork seals the easy way !](https://reader036.fdocuments.in/reader036/viewer/2022062518/56814224550346895dae398a/html5/thumbnails/8.jpg)
With the nut removed, fill the fork to the brim with kerosene, paraffin, diesel or thin oil.
Fuming Nitric acid and other dangerous liquids should be avoided !Replace the fork nut.
![Page 9: Changing fork seals the easy way !](https://reader036.fdocuments.in/reader036/viewer/2022062518/56814224550346895dae398a/html5/thumbnails/9.jpg)
Place the victim into the Patent ‘SMITHY’
press.
![Page 10: Changing fork seals the easy way !](https://reader036.fdocuments.in/reader036/viewer/2022062518/56814224550346895dae398a/html5/thumbnails/10.jpg)
Remove the wire circlip.
![Page 11: Changing fork seals the easy way !](https://reader036.fdocuments.in/reader036/viewer/2022062518/56814224550346895dae398a/html5/thumbnails/11.jpg)
Wrap some cloth around the seal
area to contain any eruptions caused
by trapped air escaping when the
seal breaks free from it’s seat.
![Page 12: Changing fork seals the easy way !](https://reader036.fdocuments.in/reader036/viewer/2022062518/56814224550346895dae398a/html5/thumbnails/12.jpg)
The fun bit !Pump away until the seal blows !
This fork required about 25mm of hydraulic jack movement before the seal broke free
![Page 13: Changing fork seals the easy way !](https://reader036.fdocuments.in/reader036/viewer/2022062518/56814224550346895dae398a/html5/thumbnails/13.jpg)
This image shows the old seals freshly
blown from the forks.
Very little kerosene escaped as I made sure that there was
no trapped air left in the fork.
![Page 14: Changing fork seals the easy way !](https://reader036.fdocuments.in/reader036/viewer/2022062518/56814224550346895dae398a/html5/thumbnails/14.jpg)
Remove the fork drain screw and
carefully pump out the kerosene into a
container. If the fluid comes out clean, you can use it for the other
fork later.As you can see in
this image, the kerosene is a bit grim and will be
disposed of.Refit the drain
screw.
![Page 15: Changing fork seals the easy way !](https://reader036.fdocuments.in/reader036/viewer/2022062518/56814224550346895dae398a/html5/thumbnails/15.jpg)
Clean the area where the new seals will fit.
![Page 16: Changing fork seals the easy way !](https://reader036.fdocuments.in/reader036/viewer/2022062518/56814224550346895dae398a/html5/thumbnails/16.jpg)
Apply a thin coat of grease to your new seals……….
I said a thin coat !
![Page 17: Changing fork seals the easy way !](https://reader036.fdocuments.in/reader036/viewer/2022062518/56814224550346895dae398a/html5/thumbnails/17.jpg)
That’s much better !
![Page 18: Changing fork seals the easy way !](https://reader036.fdocuments.in/reader036/viewer/2022062518/56814224550346895dae398a/html5/thumbnails/18.jpg)
Carefully fit the oil seal to the
chrome fork leg.
![Page 19: Changing fork seals the easy way !](https://reader036.fdocuments.in/reader036/viewer/2022062518/56814224550346895dae398a/html5/thumbnails/19.jpg)
Tap the seal into place with the
seal fitting mandrel.
![Page 20: Changing fork seals the easy way !](https://reader036.fdocuments.in/reader036/viewer/2022062518/56814224550346895dae398a/html5/thumbnails/20.jpg)
Fit the dust seal.
![Page 21: Changing fork seals the easy way !](https://reader036.fdocuments.in/reader036/viewer/2022062518/56814224550346895dae398a/html5/thumbnails/21.jpg)
Using the other end of the mandrel, carefully tap the dust seal into position
![Page 22: Changing fork seals the easy way !](https://reader036.fdocuments.in/reader036/viewer/2022062518/56814224550346895dae398a/html5/thumbnails/22.jpg)
Fit a new wire circlip.
![Page 23: Changing fork seals the easy way !](https://reader036.fdocuments.in/reader036/viewer/2022062518/56814224550346895dae398a/html5/thumbnails/23.jpg)
Undo the fork nut and fill your fork with the correct amount of fork oil.
Replace the fork nut and fit to your bike !Repeat the procedure on the remaining fork.
![Page 24: Changing fork seals the easy way !](https://reader036.fdocuments.in/reader036/viewer/2022062518/56814224550346895dae398a/html5/thumbnails/24.jpg)
Using this method, the seals can be changed in both forks in about 11 minutes !
That means more time for riding !
![Page 25: Changing fork seals the easy way !](https://reader036.fdocuments.in/reader036/viewer/2022062518/56814224550346895dae398a/html5/thumbnails/25.jpg)
CREDITS !
• Thanks to Smithy for the idea !• To my Daughter for getting this PowerPoint
presentation to work.• Members of the Aussie IT forum.
http://www.yamahait.com.au/ for their support.
• My work place for putting up with me !