How to Install Fork Seals

Install new fork seals when you observe fork oil leaking from the fork legs.

Motorcycle fork seals serve an important function in maintaining the suspension of the front end of the motorcycle. The seal holds the fork oil inside the fork tube and keeps it from leaking out. To ensure leak-free forks, you must properly install the fork seals. Careful removal of the fork tube and its inner parts is important to the success of reinstalling the fork seals. You need to replace the fork seals if you observe fork oil leaking from the fork tubes.

Things You'll Need

• Standard screwdriver set
• Fork seal installer

Instructions

1. Install the damper tube ring into the fork tube once you have assembled the damper tube. To assemble, place the tube ring on top of the damper tube and the damper spring on the bottom.

2. Install the fork spring into the fork tube, tapered side down. Push the spring until the damper tube pushes through the opening in the bottom of the fork tube. Clamp the lower stop over the damper tube to prevent it from moving down any farther.

3. Place and hold the fork and damper tubes in the slider. Exert pressure on the spring -- inside the fork tube -- and install the socket screw and washer with a standard screwdriver.

4. Install -- in this order -- the upper bushing, the seal spacer and a new fork seal over the fork tube inside the slider. Make sure that the flanged side of the seal spacer faces up. The lettered side of the fork seal should also face up.

5. Seat the fork bushing, the spacer and the seal by placing the fork seal installer over the fork tube onto the fork seal. Slightly tap the components into place with the tool.

6. Follow these steps for both fork legs.

Tips & Warnings

• You must completely remove the fork tubes from the motorcycle according to the owner's manual before installing new fork seals.

• Once you complete installation of the fork seals, you must add Type E fork oil according to the owner's manual.

• Be careful not to allow foreign material to enter the fork tubes and sliders once you have removed them to install the seals.

References

• "Softail Models Service Manual"; Harley-Davidson Motor Company; 2004