Question about 2003 HM Motard 250

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Fork recently did the film trick for cleaning my leaky seals but I believe too much fluid leaked out. Is there a way to refill (topoff) the forks somehow without disassembling? Leaving this weekend for a day of trial riding and will not have time to disassemble the forks. Only need to get through a day of trail riding... Any help would be appreciated. Having the same problem with an '02 CR125 Husqvarna w/ 45mm Marzocchi forks..

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Loosen top pinch bolts loosen caps remove forks remove springs , fill according to manual level . re-instal everything .,,,

Posted on Nov 10, 2008

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Front shock oil running all over

Unless you've had your front fork assembly serviced recently, I'd guess you've got blown oil seals in the top of the sliders on your forks. If someone serviced your forks lately, they may have put in too much oil and blown the seals. You'll have to drain the forks, disassemble the fork tube from the lower slider and replace the seal in each leaking tube. Refill the fork tube with the designated about of oil for a "dry" refill. Use this figure because the fork tube was disassembled. When you simply drain the forks without a disassembly, you cannot get all the oil out and the refill quantity is less.

Good Luck

Aug 06, 2011 | Harley Davidson FLSTC Heritage Softail...


Leaking fork seal? Try this...

When forks start leaking, a large part of the time there is actually a peice of debris in the seal, not an actual damaged seal. Here is a way to clean the seals while still installed on the bike. If this doesn't work, you'll know that your seal is indeed damaged and needs replaced. If it does work, you can put a little more gas in the tank!

WIth the forks on the bike, use a flat screw driver to pry out the forks dust seal. Slide the dust seal back a ways and clean it thoroughly. There will usually be alot of gunk in there to get out. Spray it out with carb cleaner and dry with a paper towel inside and out. Now clean the recess that contains your fork seal thoroughly with carb cleaner and paper towel.

There are a few things that can be used to clean the actual fork seal. You can buy a special made piece of plastic from mc parts catalogs, use a very thin feeler gauge, or my favorite is a piece of camera film negative.

Whatever you're using, very gently insert it about 1/2 inch between the seal and the fork tube. Be careful not to damage the seal. Now, holding your cleaning tool snug against the fork leg, slide it around the fork tube while slowly pulling out to make sure the debris is pulled out of the seal instead of pushed in. As you work around the fork, your little "tool" should be gently sweeping between the seal and the fork tube, removing peices of sand and dirt. You may do this a few times if they are really dirty. Wipe everything clean and very dry and work the forks up and down to see if you've stopped the leak. If so, wipe everything down one more time, reinstall your dust seal, and your through!

If you are working on upside down forks, make sure the area at the bottom of the fork tube (next to the casting) is clean. Often times simply bottoming the suspension out can cram dirt from this area into your seals.

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on Jun 12, 2010 | Motorcycles

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I Want to replace front fork seals on my 2004 Yam XT660X and need to know Fluid and Quantity used. Are there any manuals available for this model. I have replaced seals on some of my previous bikes.

If you want to replace them for maintainence ok.If its for a leak ,try this.Get some camera film negative.Usually in the pack of photos.Cut the notches off the side and cut one end at 45%.Slide it up into the fork seal.Now,with a sawing motion ,move it up and down and at the same time,work it around the seal.Any grit that is causing the leak will be felt.When grit is felt,pull it out,clean it and start again.It may take a few times but it works.A lot cheaper than seals all the time.Hope this helps

Feb 01, 2010 | 2004 Yamaha XT 660 X

2 Answers

2001 yzf426 front fork leak

Each fork has an outer dust seal, and an inner seal inside of that. Dirt gets between the seal lip and the fork slider and causes the oil to escape. The fix is to have them (Both sides) replaced. You need a fork seal driver tool (Size specific for the size of the fork) and something to measure out the oil amount. It's not an easy job, if you have never done it. Also... if the oil has never been changed, it's due.

Aug 19, 2009 | 2001 Yamaha YZ 426 F

1 Answer

How to replace fork seals on TE450 2008 model? How do i pull them apart and service them?

Try this before you pull the forks apart.Get some camera film.About 6 inches long.Cut off the notched area on the side.Cut the end at 45%.Now,push the cut end up into the fork seal.With a sawing action,slide the film all the way around the seal.When you get the feel of it you can feel tiny bits of grit that let the seals leak.This will stop the leak 9 times out of 10.When you feel the grit,pull the film out to remove the dirt,wipe film clean and start again.Hope this helps

Jul 29, 2009 | 2008 Husqvarna TE 450

1 Answer

08 450 kawi left side seal seeps a little

find a piece of laminate or something similar and run it around the fork seal to clean out any debris

Apr 12, 2009 | 2006 kawasaki KX 450 F

1 Answer

Leaking fork on 06 suzuki gsxr1000

Your forks have springs inside to absorb the bumps, and is fluid filled to dampen the up and down motions. Buy a fork rebuild kit at your motorcycle supply shop which has all of the seals needed and fill with the recommended oil. Make sure that everything is SPOTLESS, otherwise you will be doing the job again. Use a soft clean lint-free rag to wipe everything down. Do not use paper towel or dirty rags as they will scratch the surface the seals ride on and you will probably be doing the job again. The forks are usually drained with a bolt at the bottom of the forks and filled with a bolt at the top of the forks. Unless you have very high mileage or hit something, you shouldn't have to be doing this so soon. Any wheelies in the recent past???

Feb 25, 2009 | 2005 kawasaki EN 500 Vulcan

2 Answers

Front fork leaking oil from bottom of the seal.

This is one of the few things that I recommend you take to a shop - you need some very special tools and techniques to fix this problem. Sorry,

Dec 29, 2008 | 2004 Yamaha YZ 250 F

1 Answer


loosen top pinch bolts loosen caps remove forks remove springs , fill according to manual level . re-instal everything .,,,

Nov 10, 2008 | 2007 HM CRM F250X

1 Answer


loosen top pinch bolts loosen caps remove forks remove springs , fill according to manual level . re-instal everything .,,,

Nov 10, 2008 | 2008 HM CRE F250X

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