Ok i need to replace the fork seals on my 07 klx250. I want to learn to do them on my own the dealership wants 400.00 to change the fork seals and oil 350.00 if i remove the fork legs for them. 105.00/hr shop labour RIPOFF!!!! I purchaced all the tools, and parts to do the job, and according to the manual it does not look too hard. Can anyone give me some pointers on the prosess.

thankx

Ken

 

Most places average about $160 for fork rebuilds. I wouldn't pay $400 either.

You have the manual, and you mentioned that you have the correct tools. Keep a lint free rag handy, keep things organized and use soft jaws on the vise. Bleed the air completely and follow good house keeping. Enjoy the project.

 

All shops here in northern alberta are expensive for anything not just bikes, I had to get my truck fixed ( 1998 Dakota sport 4x4 V8)- I had the power steering pressure line changed, new belt & belt tensioner, Battery, and 1 tire repair it ended up costing 900.00 and change> 410.00 in parts and around 450.00 for labour, the rest is tax. the bike shops here charge 3-3 1/2 hour labour too do the forks (when still on bike) at 105.00/hr+tax plus parts. 160.00 is a steal from where I come from.

 

It's a pain to take pics and do a write up, but it would be great to have a reference here on KF ..
Good luck with it
Dan

 

DId you try to clean the seal first?
You can use a piece of a plastic water bottle to scrape the dirt out of the seal.
Try that first. Slide the wiper down the fork, then cut a piece of a water bottle or a tear off and slip it up the fork tube under the seal. run it around and pull down, you will see sand and dirt come out with the oil. Keep doing it until you dont see dirt anymore.

 

Good call Gary, try cleaning the seals definitely save some trouble if that's all it is. Maybe you didn't blow a seal after all.

The classic "Blew a seal" joke, only ten times funnier when told by monkeys. Flippin hilarious!!!!!
Dan

http://www.youtube.com/watch?v=2OpuuAa7gdE

 

Agreed Gary. Cleaning is the first thing to do before replacing seals. I was going off of the statement of [QUOTEOk i need to replace the fork seals on my 07 klx250.][/quote]

Things that I have used to clean fork seals to remove debris

Seal Mate from Motion Pro works good for seal cleaning (although sometimes too flimsy), playing cards are not very durable, and a thin plastic school divider with the ruler printed on it works good. (easy to cut and flexible).

 

I cannot get to my bike right now to see if it is just dirt (2-3 ft snow infront of my shed doors), went most of last summer riding it with it leaking a bit, you could tell it was leaking although there was no "oily mess" Even if my seal is not shot I wihh change them when the forks are apart, the oil needes replaced regardless, I will take pics when I do the work closer to spring, I still need a bench vise! have all the specialty tools though

Ken