Question about 2004 Honda CRF 230 F

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HOW DO I REMOVE THE FORK LEG FROM THE TUBE

I AM HAVING PROBLEMS REMOVING THE TOP DUST SEAL AND DISSASEMBLING THE LEG FROM THE TUBE (I HAVE REMOVED THE BOLT AT BOTTOM OF LEG),CAN YOU HELP ?

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If the bottom bolt and the top cap are removed then pop out the dust seal with a screwdriver and remove the clip on top of the oil seal. then you should be free to slide them apart. it may take several hard slides to pop the seal out.

Posted on Jun 28, 2009

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Remove front wheel, brake calliper etc . Undo top and bottom yoke pinch bolts and slide out fork leg. Clamp chrome tube in a soft jawed vice and remove top nut carefully as it is under some load and will fly away, (but its not too much you can hold it with your hand). Tip out remaining oil slowly so as to not loose spacer on top of main fork spring. Clamp lower aluminium leg in vice by calliper mounts and remove allen screw in extreme end (if the wheel spindle was in you couldnt see it) This is the only part that might be a problem as the inner end may turn. An impact wrench may help or if not a simple broom handle shoved up the other end is often enough. Once this bolt is removed the leg will split. Now lever out the dust cover to reveal the wire circlip holding in the fork seal. Remove the clip and lever out carefully the old fork seal. Fit new seal using a large socket and mallet or something similar and reassemble in reverse order, not forgetting to add correct amount of new fork oil.

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I have a 1974 Yamaha 650 XS that has been sitting for about 20 yrs. I am trying to separate the front fork tubes without damaging them so I can have them restored but I am having an issue getting them...


Assuming you have slackened off the fork top nut before removing the fork from the bike,and you have removed the screw in the fork lower, this secures the damper into the fork, next you will have removed the dust cover and seal retaining clip from the top of the leg, undo the fork top nut completly and remove the spring noteing which end of the spring is at the top, for replacment purposes.
Next fasten the lower of the fork into a vice on the flat ( not tubular surface of the fork leg) push the stancion all the way down to the bottom of the leg, then pull up sharply, repeating this in/out action to hammer out the seal from the leg until the seal/ bushes/ and washer have come out, this mat take some quick action movments to remove or separate the leg, forks which have not been appart in some time may need some heat on the fork seal. ARea of the lower leg

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1 Answer

Trying to remove my fork seals from 2005 ktm exc 200. I have the cartrige out but i cannot get the tubes apart or the axle end off. Is there a way the tubes come apart.


Hi, i presume from your thread you have removed the bolt securing the damper to the leg at the axle end, and you are having a problem removing the stancion from the leg, normaly you will have to remove the fork dust seal from the top of the fork leg, you will then expose the main fork seal which will be secured inside the fork leg by a clip,you will need to remove this, as the bushing inside the fork. Is secured to the stancion underneath the fork seal the only way to separate this, once the seal clip is removed, fasten the lower leg in a vice, warning fasten in the axle area and not the tube area to save damage, once secure push the fork tube all the way to the bottom, then pull up sharpley, repaeting this action will give a hammer effect from the inside of the fork, when reasembling before fixing the damper unit replace the fork stanchion, bushing, washer and seal, holding the tube. Upermost will reduce the risk of damage while replacing the seal in the moving area

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1 Answer

I do not have a motor cycle manuel and I need to replace dust covers and seals and fork oil on a 750 GSX Suzuki 89/90 Model . have you ?


hi, the obviouse thing here is to get a manual, however if you think you have the finess required to do the job its fairly straight forward, put bike on stand, raise the front wheel of ground, remove spindle from front wheel, remove calipers from forks, DO NOT REMOVE BRAKE LINES FROM CALIPERS, once you have done this you can then remove the front wheel, put spindle back through loose wheel inc spacers to keep all in place, remove front mudguard, i always tell people to try and remove the lower fork leg first leaving fork tube on the bike, some forks it is poss to do this as the busshing is fitted to the lower leg and not the chrome tube, undo the bolt in the lower fork leg on the underneath inside where the spindle fits through, once removed, using a container to catch the oil, pull dovn on the lug to remove it, if it comes of all the way you are in luck easy job, the fork can then be cleaned and new seal fitted, the manual would come in handy for fork oil levels,if the leg does not come off you will have to remove the whole leg, before you remove it undo the top nut on each leg as the yokes will hold it for you, it is difficult to undo once the fork is removed, once removed, lift up the dust seal, remove the clip, and then the spring from the top, grip the lower leg in a vice with protective jaws, on the flat surface only, to grab the tube area would damage the fork leg, once in the vice, push in the stancion fully depress and pull out sharply you may have to repeat this sevral times useing the stancion as a hammer until the seal is removed, replace in reverse order,
DO 1 FORK FIRST REASEMBLE THEN DO THE OTHER, hope this helps feel free to contact me, paul

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1 Answer

I need to change the fork seals on my 900 fireblade. do i need to split the forks.


HI WEATHER YOU NEED TO SPLIT THE FORKS OR NOT, YOU SHOULD, SOME OF THE OLDER HONDAS REMOVING THE LOWER FORK BOLT, ACCESABLE WHEN THE SPIINDLE HAS BEEN REMOVED, THIS WILL DRAIN THE OIL OUT OF THE FORK LEG THERE WILL BE A WASHER OR SEALING RING ON THIS SO BE CAREFUL NOT TO LOOSE IT WHEN YOU REMOVE THE BOLT, USING A BOWL OR CONTAINER TO CATCH THE OIL, UNDO THE BOLT IN THE LOWER FORK LEG, AFTER ALL THE OIL HAS BEEN REMOVED, PULL DOWN ON THE FORK TUBE IF THIS PULLS OUT OF THE LEG THEN YOU CAN COMPLETE THE JOB QUITE EASY, REMOVE DUST SEAL, CIRCLIP AND OIL SEAL, THE LATER WILL BE QUITE TIGHT IN THE LEG, WHEN YOU EASEMBLE THE FORK YOU WILL HAVE TO UNDO THE TOP FORK NUT TO REPLENISH TTHE OIL

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1 Answer

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Assuming the forks are off:

Turn each fork upside down and clamp the axle mount(protected) in a vice. Remove the valve from the very bottom of the fork. Turn the fork rightside up and fluid will drain out the hole you just created.

Now, use a flat screw driver to remove the dust seal from the fork. Under the dust seal, you'll see a wavy wire ring retaining the seal. Use a small tool to work this spring loaded ring out. Now, by yourself or with assistance, try to **** the upper tube out of the lower fork leg. It'll take a few tries. Each time, slide the tube back in a ways and pull out really fast. Soon, your fork seal, along the bushings and entire upper tube will pop out. Then just slide the seal up and off the top of your upper fork tube.

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1 Answer

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If you ask this question YOU should not be doing it! but your *** on the seat not mine.
Remove ...........front wheel, front fender,top fork cap and loosen lower triple clamp bolts under head light cover, forks are now out!
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3 Answers

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1 Answer

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