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En 450 fork seals

How to replace seas how much oil to put back and how much air to put back thanks

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Http://www.youtube.com/watch?v=G0dLM_IoIOQ
Great instructional video gives you all the info you need.

Posted on Nov 05, 2008

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Posted on Jan 02, 2017

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How much fork oil do I put in each leg of my zephyr 1100


Is you have taken the forks apart and changed the fork bushes, ie forks are totally dry, you will need about 520ml in each fork leg. When refilling and will the springs removed, add about 550ml per leg, the stroke the forks numerous times to expel any excess air. Then with forks compressed the oil level should be adjusted to 119mm from the top of the fork to the oil, ie the air gap to the oil. The add springs and spacers and reassemble.
Red zed.proboards.com

Sep 01, 2011 | 1992 kawasaki Zephyr 1100

1 Answer

Keep having leaking fork seals.have replaced seals and oil after every ride lately.(4)have tried two brands of seals last time disasembled whole of forks cleaned every part,shims everything and had...


G'day. A couple of suggestions-
Damage to the fork slider-chips or dings.
Too much oil in the fork on re-assembly can cause the seal to go.
Worn or loose fork bushes will flog the seal prematurely.
When you transport the bike-if you don't use a seal saver can pop the seals.

So let me help with these.

Be sure that the fork slider is not scored,dinged or damaged on th surface.

A good double check of the oil quantity is to ensure that when you have re-filled the tube with oil & primed it(worked the air out of it), the oil level should be 100 to 110 mm from the top of the leg to the oil with the fork fully compressed. If the level is less than this-drop it to 100mm.

To check the fork bushes-try pull on the front forks front to back(wobble) & feel for looseness in the bushes.

And finally-When you transport the bike-put a chock(I use an empty 5ltr oil container-but you can buy propper chocks from the bike shop) in-between the forks at top of the front wheel .
Now when you pull the front end down it will stop on the chock & stop the front forks being under excessive compression for extended periods-so it saves the fork springs from sacking out too.
I hope this proves helpfull.
Kind regards Andrew Porrelli

May 20, 2011 | Sherco 5.1i Motorcycles

1 Answer

I have a crf 450 x 2005, Can you possibly tell me what weight oil i need to use? i am changing my front fork seals. Secondly, can you tell me how much oil to put into each shock?


i used to ride motor cross and i had a bike shop i indiana honda shop has fork oil . i dont know how many cc to use the honda shop should tell you but i will look on line for it and email you back my e mail is broadusjeff@hotmail.com

Jan 13, 2011 | 2005 Honda CRF 450 R

1 Answer

Blow-by of the left front fork 'seal' (Honda M/C 1981 cm400c)\r\nI also own 1980 (same) but it doesn't have the 'air' added on top like this '81. . . 1) question: ` Could I just drain the fork oil...


Probably the reason the fork seal is blown is too much air pressure. Definitely fix the seal and put in the correct amount of oil. You do not have to put air in to the front forks if you do not want to. To properly set up your suspension, set your rear shocks first, hard for two, soft for one, etc. Now load the bike, you or you and the passenger. With the front forks set to near max pressure (only 12 to 14 pounds air pressure do not go over max recommended pressure) bounce on the motorcycle seat and bleed off the pressure in the front forks till the front and back of the bike drop together. This is the correct way to set up your suspension. A bicycle foot pump with a pressure gauge works best works best. You will be near max pressure in one small hand squeeze of the foot pump. You will find it only takes 7-8 pounds of pressure to set up your bike. Just remember, You do not have to put air pressure in to your front forks, they will work just fine. You just wont benefit from the adjustable design.

Sep 09, 2010 | 2002 Buell M2 Cyclone

1 Answer

Fork oil level


Forks can get pretty complicated. If they have been worked on it is not just re-filling with oil to a certain level. That would be the case if the seals leak a bit and all you are doing is adding oil to replace what has gotten past the seals. I am giving you a site where you can download a free factory service manual. Everything on servicing the forks and the rest of the bike is in the manual. There is a 2003 manual on the site. Your 2004 forks are the same as the 2003. All other service procedures are also the same. Go to this site and you can download a free PDF service manual. The site may take up to 20 seconds to load the complete list of manuals. Please rate my answer. Thanks!
www.carlsalter.com/motorcycle-manuals.asp

Nov 22, 2009 | 2004 Yamaha YZ 450 F

1 Answer

Can you tell me how much oil to put in an en500 forks please, Andy


If you never have put for oil into a set of forks, yes you have to check both forks. I would suggest treading lightly. If you have time and a place to block the bike as well as a manual you can do it.
Are you adding oil because the seals are leaking or do you have excessive stiction in the fork? If the seals are leaking, you will have to pull the forks and add new seal and put in exactly the right amount oil.
Do you have air seat or is it a closed fork?
For you en500 you should have a volume of oil in your service manual.

Aug 17, 2009 | 2005 kawasaki EN 500 Vulcan

3 Answers

How do I change the fork seals on a 2008 Honda CRF 250 r? Do I use a special tool? Oil? How much oil? Thanks so much for your expertise. Do I put equal amounts of oil on each side? Inner tube- outer tube?


hi,replacing the seal is quite easy,although it will sound complicated,jack up or lift the bike off the ground so that the front wheel is in the air(about 12-14 inches should be enough,remove the front wheel from the bike,remove each fork leg,this is done by undoing the bolts(4 on each leg)the front fork is quite easy to work on just do one at a time,remove the dust cover from the top of the staunchion tube(larger diameter tube),beneath that dust cover you should see a retaining clip that holds the seal in place,remove the retaining clip(and dont lose it),the seal is now ready to remove,the easiest way that i know to do this is to force a screwdriver through the body of the seal,you may need to hit the screwdriver with a hammer as some seal have a tin backing plate,put a hole through the seal on each side of the fork leg taking care not to damage the chrome of the fork leg,then use the screwdriver to lever the seal out of the fork leg,to reinstall the new seal,put a smear of grease or oil around the outside of the new seal,slide the new seal down the fork leg and seat it squarely into the fork tube,very carefully tap the new seal into place being very carefull not to damage the outer surface,i use a small piece of dowell type timber to do this as the wood doesnt damage the seal surface,i use a small ballpeen hammer to tap the wooden dowell,once you have the seal seated down the tube you should be able to see the groove for the retaining clip,reinstall the retaining clip making sure it is seated corectly,replace the dust cover,if you are going to replce the fork oil or top it up do this once the fork leg is back in the bike,repeat the whole procedure for the other fork leg,once you have done the fork seals reinslall the fork legs back into the bike and refit the front wheel,to top up the oil in each leg,simply undo the large cap on the end of the fork leg,you may have to remove the handlebars to do this,be carefull as the cap will be spring loaded and can easily fly off if you are not ready for it,top up or fill with the correct weight oil for your bike(normally a 10w oil),check with your local honda agent for the correct quantity,normally between 400-500 mls,this all sounds quite complicated but is actually quite easy and can be done with a minimal of tools,each fork shold take about 1/2 hr to do...hope this is a help to you

Jul 15, 2009 | 2005 Honda CRF 250 R

1 Answer

How to fix a leaking fork


hi there ,, if u have taken the forks out ready ,,then u already have an idea wots wot ,, wen u put the new seals on ,, be sure to well oil the seals be putting on to the fork leg,, oil up the fork leg aswell ,, with any oil to hand,, or the seal will pinch or stick as u work your way down the fork tube ,, wot i do to seat the seal in to the bottom part of the leg is use a piece of drainage plastic pipe the same diameter,,,ie, like u see on sinks and washin machines,, the white pipe, use this to push the seal down,, to be able to put on the circlip to hold them in, ,,ive known people to use a hammer and screw driver, to push seal in to its seated postion and marked the fork leg,,and put pits in the leg,, so the seal pops straight away,, avoid the hammer,, cheers,,

Jan 15, 2009 | 2005 kawasaki EN 500 Vulcan

2 Answers

How to fill the front suspension on a ktm exc 2001


If you get the sevice manual or contact a dealer to get the correct oil amount for your bike, they need to know the model and year, you have to have the forks off the bike. take the fork caps off, take the springs out compress the upper fork tube all the way and add the specified oil. if they also give you the measured amount from the top that's the best way to get both fork oil levels exact. there is a special tool that you set the oil level in millimeters and it sucks out the oil to the right level, but before you do that step after adding the oil always pull and push on the cartage rod several times to remove air from the cartage tube. you will hear the air coming out and you will feel the changes in the cartage rod as the cartage tube fills up with oil and the air is removed.
something i'm confussed on though is if you replaced a seal you would have had to brake down the fork to replace it. you would have poored the oil into a container, cleaned all the internal parts,and used a fork seal driver to install the new seal. part of your question asks where do i put the oil in? thats in the open end of the fork after you have taken off the fork cap. It sounds to me like you only replaced the dust seal on one fork. that is not going to fix your leaking fork. you need to replace the oil seal thats pressed inside of the top fork tube.

Dec 01, 2008 | 2008 KTM 200 EXC

1 Answer

Fork seals


ZERO air pressure on these forks those air valves are to get rid of any built up pressure in the tubes. I also have a 1990 851 love it! What weight of oil are you running and how much are you putting in?,,

Nov 10, 2008 | 1988 Ducati 851 Strada (Tricolore)

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