Question about 2003 kawasaki KX 125

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Wre do i begin to do fork seals on a 03 kx 125. the forks are off the bike and siteing in the garage

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  • custerd8t Jun 24, 2009

    I got the seals oil and dust covers I did my 450 a few years ago with a buddy helpin me but he moved out of town. I just dont want to screw it up takin them apart and putting them back together so any advice would help.

  • custerd8t Jun 25, 2009

    thank you very much I'am workin N/S so I will get back to you on friday. but those are wonderfull directions my wife will be riding by saterday!!

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Would like to help you with your problem, but you will need to have more than just the fork seals to complete this project. as it can be tricky for some people.

Posted on Jun 23, 2009

  • brian elder Jun 24, 2009

    first you have to remove top caps they unscrew, but make sure no bottom pressure on them you can clamp lower fork leg in vise i use a couple pieces of wood cut in a v-shape this will prevent springs from putting to much pressure on top caps. once top cap is removed you may have to push upper tube down a bit their should be i think a 19mm nut under the cap place wrench on it while having a ratchet and socket to hold top cap. remove the fork spring and fork spring seat take out. push upper tube all the way down and remove the damping adjuster,from the push rod. remove fork from vise and tip to drain oil pump the push rod a least 10 to 12 xs to remove oil.place fork in vise remove bottom cylinder valve in bottom of fork you might have to place a long xtension rod with a socket on it inside upper fork tube to keep it from spinning i think its a 12mm supposed to use a special tool but never had to. after thats loosend you should be able to remove the cylinder assembly from the tube. now where your fork seals are lift up the spring band and slide the dust seal up, you should see a retaining ring use a awl or small screwdriver to remove the retainer ring,grab both ends of tube and push and pull a couple times and tube should seperate i do suggest that you replace the guide bushings and oil seals basically replace in order but put a plastic bag over fork tube to prevent seals from being torn wipe a little oil on them before replacing you should be able to install in order to put fork back toghether fill with oil but pull push rod up and down to remove air bubbles.

  • brian elder Jun 24, 2009

    to install the fork seals i have a fork seal installer but you can use a piece of pvc pipe split into to drive the seal home. i hope this helps you as it kinda hard to explain but you shouldnt have a problem. and only do one at a time lay every thing out the way it came out to ease the process.

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