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TOPIC: Installing Fork Seals

Installing Fork Seals 12 Feb 2018 06:28 #1

  • Dave The Wave
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Does it matter if the fork seals are installed with the exposed spring "up" or "down". See picture. Spring "up" is on the left and spring "down" is on the right.



I'm in the middle of assembly so please let me know.

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Installing Fork Seals 12 Feb 2018 06:55 #2

  • 1971DT250
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Spring side down.

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The hours spent riding my Enduros is not deducted from my life span.

Installing Fork Seals 12 Feb 2018 07:33 #3

  • Dave The Wave
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Having problems. It looks like the old seals were installed spring within the seal "up". The new seals are larger in diameter. See picture. The old seals have a slight "lip" that catches on a ledge within the outer-fork housing which then allows enough room for the washer and retaining clip. The new seals can't get by that ledge. I don't want to pound the crap out of the new seals. Any suggestions or words of wisdom?

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Installing Fork Seals 12 Feb 2018 17:45 #4

  • Scootern29
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Do not assume the old seals are correct. If you look at your old seal with the lip on it, by the picture, they look very close to the same diameter. The last 3 sets of seals I have used came from Parts Unlimited and they were a little thicker and I could not use the washer which really is not a big deal and have had no problems. The retaining clip in theory holds the seal in. I would doubt once you press the seals in they are going to back out. I've worked on lots of different European forks and they are press in seals without clips of any kind.
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Installing Fork Seals 12 Feb 2018 19:31 #5

  • mdscott
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Yeah Scootern, seems I remember stacking two Yamaha Venture seals in my Husky and leaving out the retaining clip.

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Thanks Mark
Roseville, Ca.

74 DT250
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Installing Fork Seals 12 Feb 2018 19:45 #6

  • Dave The Wave
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These new seals are 139/1000 larger (diameter) than the original ones and will only fit into the fork tubes about 3/8 of an inch. If you look at my 1st picture you'll see a slight ledge about 3/8" into the tube. They can't get past that ledge and simply stick out of the tube. They're just too big in diameter. If you look at my comparison picture, you can see the new ones are larger in diameter.

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Last Edit: by Dave The Wave.

Installing Fork Seals 12 Feb 2018 19:59 #7

  • RT325
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Hard to see how the old seal went in past the lip or is the lip the correct OD & the rest of it below that was just going along for the ride. Should be 34 ID. 46 OD. 10.5 thick. I cheated & google that but should know off by heart. Re-reading, did the old seal virtualy fall out with clip removed. Measure them up, should be 46mm maybe plus a whisker to make it rubbery tight. Grease it & the fork inner bit. Can you drive it using the old seal. Not my favorite job doing seals. ps, reading again i see you say old seal 'lip' only went up to the ledge, not past it.

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Installing Fork Seals 12 Feb 2018 21:59 #8

  • plaibike
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DTW, what is the diameter of the "Lip" on the old seal Vs the diameter of the new seal?

Also, my go to trick with bearings, u-joint caps, seals, etc., is to throw them in the deep freezer, have a beer, then try installing them. Works 99% of the time.

Or if you are in Western Canada this week, throw them in the snow bank for an hour and they should be good to go:)
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Installing Fork Seals 13 Feb 2018 05:18 #9

  • Pillsbury
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looks like the wrong seal. :S

The O.D. & I.D. must be identical. Most seals also show size (like 24x34x10, etc) so just make sure you match them. Unless you are doing a 10 point resto & need "yamaha" there are many others that will fit. The seals in my DT1 with the Suzuki X6 front end are from Honda :)
Many Japanese bikes used forks that were of the same exact size.
Just a hint......When I replace seals or bearings I always start my search with the size & try to get made in Japan or other good quality from an Industrial country (NOT CHINA!!) I only use OEM when I can't find the same thing for 1/2 the price. Good luck, I use PVC pipe for the local hardware store for most of my seal drivers. with different sizes of pipe + PVC fittings you can usually find a piece that will fit.........
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1970 DT1-C Grand Prix race bike
1979 DT1-C Dirt bike
1973 Honda CR250
1974 Honda MR-50
1966 Triumph Tiger Cub
1967 Moto Guzzi V700
1968 Honda CL90
Last Edit: by Pillsbury.

Installing Fork Seals 13 Feb 2018 08:03 #10

  • Scootern29
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And....never ever, ever, ever use leak proof seals. They leak.
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