I have a 1976 yz 125 x. I would like to know how to pull the forks apart to replace seals. They are the air over oil forks. @
These are pretty easy if these are stock forks,,, you can actually do it without losing any for oil. I used to do it all the time in the dealership. DO NOT remove the fork caps yet,,just loosen the cap about 2 turns. Remove the forks from the bike, Secure them, one at a time in a vertical position, I had a LARGE vice sitting on the floor. You want to remove the cap now and hold onto the fork leg so it does not slide down real fast!!!! Ease it down until the spring shows, remove the spring almost all the way until all the oil drips off the spring, remove it and lay it somewhere clean. Slowly lower the leg into the slider, remove the seal protector, Look at the fork seal, there is a snap ring that holds the seal in, carefully remove it. Take a 4mm drill bit (.160"+-) and drill two holes in the top of the seal, 180 apart. I had a "hook" tool I used to work the seal out. Once its out, slide it up and over the tube, CLEAN the fork tube!! CAREFULLY oil the new seal and carefully work it over the tube, slide it into place and work it down, now with a FLAT drift tap a little at a time until you can install the snap ring fully seated!! Raise the tube, install the spring and cap. Once the tubes are installed in the triple clamps you can fully tighten the caps! Repeat for the other one and reinstall. TAKE YOUR TIME!!
SOURCE: oil amount in forks
Check the service manual I sent you. All sorts of good information in it.
Again, please rate this answer. > four diamonds would be nice.
SOURCE: 2002 kx 125 fork oil level
3.5 inches to 5 inches from the top of the fork with the cap removed.
SOURCE: front fork leaking oil from bottom of the seal.
Before you take it to the shop try this.Get some camera film,Cut the notched edge of it and trim the top to an angle of 45 deg..Slide this up into the fork seal and working it up and down,slide it all the way around the seal.When you get the feel of it,you can feel tiny bits of grit.This will clean the grit out 99% of the time.I always keep a piece of film in the toolbox.
SOURCE: What are the specs for fork oil in a 99 YZ 125
Use a good quality 5Wt suspension oil (or 7Wt if you want more dampening but this will make it a little more stiff through the small stuff). With the springs removed, fill the forks to the top, cycle the damper rod up and down until it has consistant and firm resistance, top the fluid off to the top, lift the outer tube up about 6" then set it back down, top off, then let it sit until you see no more bubbles. Stroke the damper rod again to ensure there is no air and then **** out fluid until your level is between 110 and 150MM in each tube. Make sure each tube is filled to the same level. One quart per fork is enough to do the job but you might need three quarts to have both filled prior to sucking the excess back out. I usually start with three bottles.
For a firmer feel, use more oil (110MM). For a softer feel, use less fluid (150MM). This is measured from the top of each tube to the level of the oil. Just use a piece of clear tubing and an irrigation syringe - you can get one from a local animal vet. Just mark the tubing with a sharpie at the level you desire.
My standard setting was 135MM from the top using 7Wt oil. I am 160lbs and a mid pack A class rider using essentially stock valving with stock springs.
Testimonial: "Thank you very much this is the first actual answer i have gotten on this question. I appreciate the help. LIVE TO RIDE "
306 views
Usually answered in minutes!
×