How hard is it to replace fork seals?
 

I'd like to do it myself since the repair shops want 100-150 dollars for ONE fork to be done... even with the forks off the bike. That's a rip off in every sense of the word(s).

I hear you need a special tool so does anyone know where to get it? I'm very mechanically inclined so I don't think I would have a problem doing it.

Here ya go. The special tools you need are a seal driver and a fork oil level tool.
The fork's in the video are not from a klx but you'll get the idea anyway
http://www.youtube.com/watch?v=W2G-b66F3es

http://www.youtube.com/watch?v=Xoep9...eature=related
http://www.youtube.com/watch?v=Xoep9...eature=related

Thanks for the links, I watched them and decided I'm gonna give it a try. What really sucks is that the Fork Seal Driver at motosport.com is $60!

I use a piece of PVC pipe that I split in half length wise to drive the new seals in. Don't use a metal hammer as it could nick the fork tube.

Ride on
Brewster

PlanetKLX also uses the PVC driver method. Looks like a good plan to me, less likely to scratch your tube. You just saved youself enough money for a new tire/or ?!

Well, I screwed it up. I don't feel like explaining what I did because I'm royally frustrated at the moment. What are my choices for aftermarket front forks that cost under $100,000?

1991-1995 Kawasaki KX 125, 250, 500 forks will bolt in but you will need adapters to use the KLX axle with them.

Some good information here:

http://www.planetklx.org/techtips/kx...-forkswap.html

Ride on
Brewster

There's no way you F'd those things up so bad that you can't send them out to get rebuilt. Motopro,factory connection,etc etc. Someone can do it.

Turns out I didn't screw up enough to make the forks leak more, and they are sealed and working properly so far. So I thought I would let you all know and thanks for the help!