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Fork seal replacement

Scheduled Pinned Locked Moved DTX
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  • S Offline
    S Offline
    SpookDog
    wrote on 6 Apr 2023, 10:16 last edited by
    #12

    £17 genuine on eBay, just search ‘dtr fork bottom bolts’

    1 Reply Last reply
    1
    • S SpookDog
      4 Apr 2023, 11:07

      If you’re replacing the seals you may as well replace the bushes at the same time (Brooks suspension sells top & bottom bushes)…
      You can use an old broom handle to tap into the 27mm female fitting inside the fork and turn/hold it with pipe grips…
      Any seize/sticking is usually the 10mm Allen bolt head being corroded to the ally fork bottom (not the threads) White crusty crap builds up between the two different metals. I use silicon sealant to fill & seal the gap between the two, or at least cover and waterproof the bottom of the forks…

      I’ve had to drill out the Allen bolts from both sets of forks I’ve worked on. I drilled them out to 10.5 - 11mm then hammered the Allen key into them and got good purchase. Loads of heat was needed! Even after I’d undone and removed the inner (with a 27mm tool-bit I bought for £22) and it was just the bolt head stuck in the fork bottom!!…

      C Offline
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      CalDT125
      wrote on 6 Apr 2023, 13:42 last edited by
      #13

      @SpookDog The one leg stripped nice and easily. I left the one i suspected to be a nightmare last and it is. Head of the allen bolt ceased in the bottom of the fork leg. Tonnes of heat and a meter long breaker bar with my fat self bouncing off the end of it still wont crack it free 🤣. Impact gun wont free it either. May run it to a car garage local and get one of their windy guns on it. By the state of the first stripped leg i will be replacing bushes too. Brooks suspension you mentioned a few posts ago i looked at but i cant seem to see them stocking the ones i need + all i can find is pyramid ones being sold everywhere which i remember someone mentioning was crap?. Any ideas where else to try? Also there was no 27mm hex on the top of the damper rod it was just smooth 🤣. Tapped a broom stick into it though and worked fine thankfully, wish the same could be said for the other 🙄

      S 1 Reply Last reply 6 Apr 2023, 14:42
      0
      • C CalDT125
        6 Apr 2023, 13:42

        @SpookDog The one leg stripped nice and easily. I left the one i suspected to be a nightmare last and it is. Head of the allen bolt ceased in the bottom of the fork leg. Tonnes of heat and a meter long breaker bar with my fat self bouncing off the end of it still wont crack it free 🤣. Impact gun wont free it either. May run it to a car garage local and get one of their windy guns on it. By the state of the first stripped leg i will be replacing bushes too. Brooks suspension you mentioned a few posts ago i looked at but i cant seem to see them stocking the ones i need + all i can find is pyramid ones being sold everywhere which i remember someone mentioning was crap?. Any ideas where else to try? Also there was no 27mm hex on the top of the damper rod it was just smooth 🤣. Tapped a broom stick into it though and worked fine thankfully, wish the same could be said for the other 🙄

        S Offline
        S Offline
        SpookDog
        wrote on 6 Apr 2023, 14:42 last edited by SpookDog 4 Jun 2023, 15:43
        #14

        @CalDT125

        The bushes are sold by size, not listed by make or model. I’ll post the size in a couple hours when I get back to the batcave 🙂

        The fork inner has a female 12-sided hole that takes a 27mm Allen key type tool. I’m glad that the broom handle worked though! 😛
        Maybe get a needle and try scratching away at the bit between the bolt head and the ally? It took a stupid amount of heat when I did mine. You can try turning it the other way (righty~tighty) a bit as well, it cracks them off sometimes! Good luck, keep at it. It will come out eventually 🤞

        S 1 Reply Last reply 6 Apr 2023, 16:54
        1
        • S SpookDog
          6 Apr 2023, 14:42

          @CalDT125

          The bushes are sold by size, not listed by make or model. I’ll post the size in a couple hours when I get back to the batcave 🙂

          The fork inner has a female 12-sided hole that takes a 27mm Allen key type tool. I’m glad that the broom handle worked though! 😛
          Maybe get a needle and try scratching away at the bit between the bolt head and the ally? It took a stupid amount of heat when I did mine. You can try turning it the other way (righty~tighty) a bit as well, it cracks them off sometimes! Good luck, keep at it. It will come out eventually 🤞

          S Offline
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          SpookDog
          wrote on 6 Apr 2023, 16:54 last edited by
          #15

          Upper bushes: 45mm x 12mm x 2mm
          Lower bushes: 41mm x 20mm x 1mm

          They are sold in pairs, I made the mistake of thinking they were single and ordered 2 of each and ended up with 4 of each! They are good quality with Teflon coating on the relevant side for extra ‘slippy’ 🙂 …

          Let us know how you get on bud…

          1 Reply Last reply
          1
          • C Offline
            C Offline
            CalDT125
            wrote on 6 Apr 2023, 18:16 last edited by
            #16

            Managed to strip down both fork legs and cleaned them all up. Few replacement parts i need to get hold of. Main thing being all 4 bushes, cant seem to find them anywhere but can find somewhere that sells various sizes just not under the name of the bike so if anybody knows the size or where i can find the sizes for the bushes needed for a 2005 DT125x id be massively appreciative.
            Will also be replacing the clip above the oil seal, the O ring around the top nut and the allen bolts at the bottom with the crush washers and of course the oil and dust seals. Already found most of that but just need to know where to get the bushes from or at least know where i can find the dimensions for them. Cheers people 👍

            S 1 Reply Last reply 6 Apr 2023, 18:46
            0
            • C CalDT125
              6 Apr 2023, 18:16

              Managed to strip down both fork legs and cleaned them all up. Few replacement parts i need to get hold of. Main thing being all 4 bushes, cant seem to find them anywhere but can find somewhere that sells various sizes just not under the name of the bike so if anybody knows the size or where i can find the sizes for the bushes needed for a 2005 DT125x id be massively appreciative.
              Will also be replacing the clip above the oil seal, the O ring around the top nut and the allen bolts at the bottom with the crush washers and of course the oil and dust seals. Already found most of that but just need to know where to get the bushes from or at least know where i can find the dimensions for them. Cheers people 👍

              S Offline
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              SpookDog
              wrote on 6 Apr 2023, 18:46 last edited by SpookDog 4 Jun 2023, 19:52
              #17

              @CalDT125

              Check the post above! They are the fork~bush sizes for a dtr125 which have 41mm forks. I don’t know if dtx’s are different. (Edit!) I checked the Haynes manual and it just says ‘DT’ models, so I’m guessing that the above sizes are for Dtx forks as well. They work out about £20 or so if I remember correctly…

              The clips are 56mm and about a fiver for stainless steel ones on eBay. Again, the Allen bolts (genuine) are £17 a pair on eBay…

              C 1 Reply Last reply 6 Apr 2023, 20:19
              1
              • S SpookDog
                6 Apr 2023, 18:46

                @CalDT125

                Check the post above! They are the fork~bush sizes for a dtr125 which have 41mm forks. I don’t know if dtx’s are different. (Edit!) I checked the Haynes manual and it just says ‘DT’ models, so I’m guessing that the above sizes are for Dtx forks as well. They work out about £20 or so if I remember correctly…

                The clips are 56mm and about a fiver for stainless steel ones on eBay. Again, the Allen bolts (genuine) are £17 a pair on eBay…

                C Offline
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                CalDT125
                wrote on 6 Apr 2023, 20:19 last edited by
                #18

                @SpookDog Ace mate cheers for that! Will get them ordered up 👍. Yeah it did finally crack after a hell of allot of heat and effort 🤣. I'll get the dremel on it and open up the base of the leg a tad so the tolerance isn't so close between the bolt and fork perhaps. One crush washer is ceased solid in there so hopefully that'll allow me to get that out a bit easier too to replace. I'll no doubt strip them again next winter and get them powder coated as they are in a bit of a state but the aim is just to have a bit of fun this summer while i get my other bike sorted. Also the damper rods in my forks dont have the 27mm hex or infact any kind of way of undoing them from the inside its just smooth so i'll be getting a refund on that £24 tool i bought the other day haha thankfully the broom handle saved the day 🤣. Slight pitting high up on the stancion not really in reach of the seals unless i go flying off an mx jump to flat but any ideas with whats best for sorting them out a bit? From what ive seen online people use a bit of 1500 grit to take the high points off and maybe even using some kind of expoxy resin to fill the pits if needed. May look into that a bit more in the meantime too. Thanks again mate for the help, much appreciated

                S 1 Reply Last reply 7 Apr 2023, 11:28
                0
                • C CalDT125
                  6 Apr 2023, 20:19

                  @SpookDog Ace mate cheers for that! Will get them ordered up 👍. Yeah it did finally crack after a hell of allot of heat and effort 🤣. I'll get the dremel on it and open up the base of the leg a tad so the tolerance isn't so close between the bolt and fork perhaps. One crush washer is ceased solid in there so hopefully that'll allow me to get that out a bit easier too to replace. I'll no doubt strip them again next winter and get them powder coated as they are in a bit of a state but the aim is just to have a bit of fun this summer while i get my other bike sorted. Also the damper rods in my forks dont have the 27mm hex or infact any kind of way of undoing them from the inside its just smooth so i'll be getting a refund on that £24 tool i bought the other day haha thankfully the broom handle saved the day 🤣. Slight pitting high up on the stancion not really in reach of the seals unless i go flying off an mx jump to flat but any ideas with whats best for sorting them out a bit? From what ive seen online people use a bit of 1500 grit to take the high points off and maybe even using some kind of expoxy resin to fill the pits if needed. May look into that a bit more in the meantime too. Thanks again mate for the help, much appreciated

                  S Offline
                  S Offline
                  SpookDog
                  wrote on 7 Apr 2023, 11:28 last edited by SpookDog 4 Jul 2023, 12:32
                  #19

                  @CalDT125

                  I left my seized washers in and used them again last time, not the best solution but it worked!…
                  I use silicone sealant on the bolt heads before fitting them in. After it’s all torqued up I cover the bolt and hole as well…

                  I use fine wire wool to remove rust, aluminium foil works as well. Any pits I fill with chemical metal/epoxy filler-adhesive. I’ve used it on bad pits in the ‘seal zone’ before with good results. I’m sure that there’s better, proper methods of repair that I don’t know about 🙂 …

                  C 1 Reply Last reply 7 Apr 2023, 11:41
                  0
                  • S SpookDog
                    7 Apr 2023, 11:28

                    @CalDT125

                    I left my seized washers in and used them again last time, not the best solution but it worked!…
                    I use silicone sealant on the bolt heads before fitting them in. After it’s all torqued up I cover the bolt and hole as well…

                    I use fine wire wool to remove rust, aluminium foil works as well. Any pits I fill with chemical metal/epoxy filler-adhesive. I’ve used it on bad pits in the ‘seal zone’ before with good results. I’m sure that there’s better, proper methods of repair that I don’t know about 🙂 …

                    C Offline
                    C Offline
                    CalDT125
                    wrote on 7 Apr 2023, 11:41 last edited by
                    #20

                    @SpookDog Yeah i may have to do that if it comes to it then. Hitting dead ends everywhere trying to find a set of bushes though. Cant find anywhere with the measurments you privided. I have phoned around and everywhere to main dealers and suspension specialists and all im getting is that the parts for these forks have been discontinued. May have to just look into doing a fork conversion if i cant find any or just hope that the bushes i have that come out them initially arent as mashed as they look 🤣. Not ideal but i cant see any other options

                    S 1 Reply Last reply 7 Apr 2023, 13:00
                    0
                    • C CalDT125
                      7 Apr 2023, 11:41

                      @SpookDog Yeah i may have to do that if it comes to it then. Hitting dead ends everywhere trying to find a set of bushes though. Cant find anywhere with the measurments you privided. I have phoned around and everywhere to main dealers and suspension specialists and all im getting is that the parts for these forks have been discontinued. May have to just look into doing a fork conversion if i cant find any or just hope that the bushes i have that come out them initially arent as mashed as they look 🤣. Not ideal but i cant see any other options

                      S Offline
                      S Offline
                      SpookDog
                      wrote on 7 Apr 2023, 13:00 last edited by
                      #21

                      @CalDT125

                      Brooks suspension. It was recommended to me by a forum member, and they are top quality for not much money…

                      S 1 Reply Last reply 7 Apr 2023, 13:03
                      0
                      • S SpookDog
                        7 Apr 2023, 13:00

                        @CalDT125

                        Brooks suspension. It was recommended to me by a forum member, and they are top quality for not much money…

                        S Offline
                        S Offline
                        SpookDog
                        wrote on 7 Apr 2023, 13:03 last edited by SpookDog 4 Jul 2023, 14:15
                        #22

                        Sorry Brook suspension. Go to website:

                        Then use the left hand button (looks like a = but with 3 lines) in the tool bar for:

                        Front end: then
                        Forks bushes: then
                        Guide bushes: then
                        Then change to search by product name they will be in dimensions…

                        Do it with ‘slide bushes’ as well. Guide is top bushes and Slide is bottom bushes.
                        Good luck, let us know if you have any problems. Or how you get on 🙂 …

                        S 1 Reply Last reply 7 Apr 2023, 13:23
                        0
                        • S SpookDog
                          7 Apr 2023, 13:03

                          Sorry Brook suspension. Go to website:

                          Then use the left hand button (looks like a = but with 3 lines) in the tool bar for:

                          Front end: then
                          Forks bushes: then
                          Guide bushes: then
                          Then change to search by product name they will be in dimensions…

                          Do it with ‘slide bushes’ as well. Guide is top bushes and Slide is bottom bushes.
                          Good luck, let us know if you have any problems. Or how you get on 🙂 …

                          S Offline
                          S Offline
                          SpookDog
                          wrote on 7 Apr 2023, 13:23 last edited by
                          #23

                          It might be 40.70 x 20 x 1
                          for the lower bushes. I measured with a ruler!…

                          They are both on the second page of their sections 🙂 again! Good luck!…

                          S 1 Reply Last reply 7 Apr 2023, 13:38
                          0
                          • S SpookDog
                            7 Apr 2023, 13:23

                            It might be 40.70 x 20 x 1
                            for the lower bushes. I measured with a ruler!…

                            They are both on the second page of their sections 🙂 again! Good luck!…

                            S Offline
                            S Offline
                            SpookDog
                            wrote on 7 Apr 2023, 13:38 last edited by SpookDog 4 Jul 2023, 14:39
                            #24

                            Actually, thinking about it, they are probably 41.7 x 20 x 1
                            If the fork Stantions are 41 then the bushes will be slightly wider so they are the sacrificial surface that connects. Not the stantion!…

                            I was given the original dimensions in a post on this site last year. I’ll search for it later…

                            S 1 Reply Last reply 7 Apr 2023, 13:48
                            1
                            • S SpookDog
                              7 Apr 2023, 13:38

                              Actually, thinking about it, they are probably 41.7 x 20 x 1
                              If the fork Stantions are 41 then the bushes will be slightly wider so they are the sacrificial surface that connects. Not the stantion!…

                              I was given the original dimensions in a post on this site last year. I’ll search for it later…

                              S Offline
                              S Offline
                              SpookDog
                              wrote on 7 Apr 2023, 13:48 last edited by
                              #25

                              Found it! Correct size for ‘bottom’ ‘slide’ bushes are:
                              41.70mm x 20mm x 1mm

                              Sorry for the confusion!…

                              C 1 Reply Last reply 7 Apr 2023, 21:33
                              2
                              • S SpookDog
                                7 Apr 2023, 13:48

                                Found it! Correct size for ‘bottom’ ‘slide’ bushes are:
                                41.70mm x 20mm x 1mm

                                Sorry for the confusion!…

                                C Offline
                                C Offline
                                CalDT125
                                wrote on 7 Apr 2023, 21:33 last edited by
                                #26

                                @SpookDog Haha no worries mate. Had me looking everywhere for 41.00mm 🤣🤣. Yeah i found another post on here and the guy had ordered them ones off brooks and said they worked perfectly so i ordered them up earlier. Ordered some paints too so should have some pretty fresh forks by the end if all goes well. Going to strip the paint off them tomorrow and address any pitting on the stancions etc

                                S 1 Reply Last reply 7 Apr 2023, 22:04
                                0
                                • C CalDT125
                                  3 Apr 2023, 16:50

                                  @HOTSHOT-III Absolute perfect response mate was just what i was hoping for haha thanks mate. I dont have a spare spindle unfortunately but i could definitely knock something up to do the job perfectly just needed those sizes you've provided. Cheers for that 👍

                                  Hybrid_Theory01H Offline
                                  Hybrid_Theory01H Offline
                                  Hybrid_Theory01
                                  wrote on 7 Apr 2023, 21:36 last edited by
                                  #27

                                  @CalDT125 Im currently rebuilding my suspension,

                                  1 Reply Last reply
                                  1
                                  • C CalDT125
                                    7 Apr 2023, 21:33

                                    @SpookDog Haha no worries mate. Had me looking everywhere for 41.00mm 🤣🤣. Yeah i found another post on here and the guy had ordered them ones off brooks and said they worked perfectly so i ordered them up earlier. Ordered some paints too so should have some pretty fresh forks by the end if all goes well. Going to strip the paint off them tomorrow and address any pitting on the stancions etc

                                    S Offline
                                    S Offline
                                    SpookDog
                                    wrote on 7 Apr 2023, 22:04 last edited by
                                    #28

                                    @CalDT125

                                    Sweet! As long as you got the proper ones 😬

                                    S 1 Reply Last reply 8 Apr 2023, 13:16
                                    1
                                    • S SpookDog
                                      7 Apr 2023, 22:04

                                      @CalDT125

                                      Sweet! As long as you got the proper ones 😬

                                      S Offline
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                                      SpookDog
                                      wrote on 8 Apr 2023, 13:16 last edited by SpookDog 4 Aug 2023, 14:17
                                      #29

                                      Also get yourself a decent size tub of red rubber grease. Grease the station bottoms when you assemble it, as well as the seals & bushes…

                                      It’s wicked stuff for fitting tyres as well. Grease under the rubber strip to waterproof the spoke tops inside the rim, as well as for slipping the tyre on 🙂 …

                                      It’s good with calliper piston & seals as well…

                                      First time I saw it used was on ‘Wheeler Dealers’! Anton slavered it on a calliper piston with a brush! 😛 I did some searching on the web after that and was surprised I’d never seen it before…

                                      S 1 Reply Last reply 10 Apr 2023, 16:46
                                      1
                                      • S SpookDog
                                        8 Apr 2023, 13:16

                                        Also get yourself a decent size tub of red rubber grease. Grease the station bottoms when you assemble it, as well as the seals & bushes…

                                        It’s wicked stuff for fitting tyres as well. Grease under the rubber strip to waterproof the spoke tops inside the rim, as well as for slipping the tyre on 🙂 …

                                        It’s good with calliper piston & seals as well…

                                        First time I saw it used was on ‘Wheeler Dealers’! Anton slavered it on a calliper piston with a brush! 😛 I did some searching on the web after that and was surprised I’d never seen it before…

                                        S Offline
                                        S Offline
                                        SpookDog
                                        wrote on 10 Apr 2023, 16:46 last edited by
                                        #30

                                        Has anyone who’s fitted new seals had the 1 or 2 washers that go between the top-bush and lower-seal and the 2 seals? I’ve never had 1 fitted let alone 2 …

                                        1 Reply Last reply
                                        0
                                        • HOTSHOT IIIH HOTSHOT III
                                          4 Apr 2023, 08:57

                                          @Hybrid_Theory01 said in Fork seal replacement:

                                          @Hybrid_Theory01 (torque it to 25NM)

                                          Do you mean the damper rod bolt at the bottom of the fork leg? This should be tightened to 62Nm with a new copper washer and Loctite. It's a safety critical fastener.

                                          Hybrid_Theory01H Offline
                                          Hybrid_Theory01H Offline
                                          Hybrid_Theory01
                                          wrote on 26 Apr 2023, 13:08 last edited by
                                          #31

                                          @HOTSHOT-III yes you are right 25 mm is for the top, the bottom damper Bolt requires 62 mm, i used a new Copper washer but not loctite since Yamaha manual does not mention it

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