If you’re an avid motorcycle rider, chances are you’ve heard of Ohlins fork seals. These high-performance seals are renowned for their durability and ability to provide a smooth ride. However, like any other component, fork seals can wear out over time and need to be replaced. The good news is that changing Ohlins fork seals is a straightforward process that can be done at home with a few basic tools and some patience.
Before you start the process, it’s essential to have a clear understanding of the signs that your fork seals may need to be replaced. Common indications include oil leaking from the fork tubes, excessive play or movement in the forks, and reduced suspension performance. If you’re experiencing any of these issues, it’s time to roll up your sleeves and get to work.
The first step in changing Ohlins fork seals is to remove the front wheel and any fairings or guards that may be obstructing access to the forks. Once you have clear access, you’ll need to release the fork caps and loosen the front axle pinch bolts. With these bolts loose, you can remove the front axle and slide the wheel out of the forks.
Next, you’ll need to remove the lower fork leg from the fork tube. This can be done by loosening the lower fork pinch bolts and sliding the fork leg down carefully. Take caution to avoid scratching or damaging the fork tube during this step. Once the lower fork leg is off, you can drain the oil and remove the old seal. A seal puller or a small screwdriver can be used to carefully pry the seal out of its groove.
How to Change Ohlins Fork Seals
If you’re experiencing leaks or suspension issues with your Ohlins forks, it may be time to change the fork seals. This guide will take you step-by-step through the process of changing the fork seals on your Ohlins forks.
Before you begin:
- Gather all the necessary tools and materials, including new fork seals, fork oil, an Ohlins fork seal driver, a fork oil seal driver, a fork oil level tool, a fork spring compressor, a torque wrench, and a set of Allen keys.
- Make sure you have a clean and organized workspace to work in.
- Read your bike’s manual for any specific instructions or precautions.
Step 1: Prepare the bike
Start by placing your bike on a stable stand or lift to elevate the front end and remove the front wheel. This will give you better access to the forks.
Step 2: Remove the fork caps
Using the appropriate size Allen key, loosen and remove the fork caps. Be cautious as residual pressure may be released when loosening the fork caps. Make sure to safely catch any oil that may spill out.
Step 3: Remove the fork from the bike
Next, remove the forks from the bike. You may need to refer to your bike’s manual for specific instructions on how to remove the forks.
Step 4: Drain the fork oil
Once the fork is removed, turn it upside down and fully compress the fork to drain the fork oil. Be sure to catch the oil in a drain pan. Once fully compressed, extend the fork and repeat the process to ensure all the oil has been drained.
Step 5: Remove the dust seal and clip
Using a small flathead screwdriver, gently pry the dust seal away from the fork. Once the dust seal is removed, you will have access to the retaining clip. Use a pick tool or small screwdriver to carefully remove the retaining clip.
Step 6: Remove the old fork seal
With the retaining clip removed, slide the old fork seal down the fork tube. If the seal is stuck, you may need to use a seal pick or a small screwdriver to carefully pry it out.
Step 7: Install the new fork seal
Apply a small amount of fork oil on the new fork seal, then slide it onto the fork tube. Make sure the seal is properly seated and aligned. Use the fork oil seal driver to press the seal into place.
Step 8: Reassemble the fork
Once the new fork seal is in place, reassemble the fork by reversing the previous steps. Make sure to refer to your bike’s manual for specific torque settings and assembly instructions.
Step 9: Fill with fork oil
With the fork assembled, refill it with the appropriate amount of fork oil, as specified in your bike’s manual. Use the fork oil level tool to ensure the correct oil level is achieved.
Step 10: Reinstall the fork
Now that the fork is reassembled and filled with oil, reinstall it onto your bike according to your bike’s manual. Make sure all fasteners are properly tightened.
Step 11: Test the fork
After reinstallation, test the fork to ensure it is working properly. Compress and extend the fork several times to check for any abnormalities or leaks. If everything looks and feels good, you’re done!
Changing the fork seals on your Ohlins forks can improve their performance and prevent further damage. By following these steps and taking your time, you can successfully change the fork seals and get back on the road with confidence.
Preparing for the Fork Seal Replacement
Before beginning the fork seal replacement, it is important to gather all the necessary tools and equipment. Here is a list of items you will need:
- Socket set
- Torque wrench
- Fork oil
- Fork seal driver
- Fork dust seal
- Fork seal cleaner
- Shop towels
- Safety glasses
Additionally, it is essential to have a clean and well-lit workspace. Ensure that you have enough room to work comfortably and that the area is free from debris and other obstructions. Having a bike stand or lift can also help support the front end of the motorcycle during the process.
Before starting the fork seal replacement, it is worth considering replacing other components such as the fork bushings or oil seals if they are worn or damaged. This will prevent any future issues or leaks.
It is also crucial to consult the manufacturer’s manual or service guide for your specific bike model to ensure that you follow the correct procedures and torque specifications. Each motorcycle may have slightly different requirements for fork seal replacement.
Finally, it is recommended to take pictures or make notes of the current fork assembly configuration. This will help during reassembly to ensure that all parts are placed properly and in the correct order.
By gathering the necessary tools, preparing a clean workspace, and familiarizing yourself with the manufacturer’s instructions, you are ready to begin the fork seal replacement process.
Removing the Forks from the Bike
Before you can change the Ohlins fork seals, you will need to remove the forks from your bike. Here’s a step-by-step guide on how to do it:
- Start by placing your bike on a sturdy stand or lift to ensure stability and safety.
- Loosen the front axle pinch bolts using an appropriate socket or wrench.
- Using a socket and ratchet, remove the front axle bolt and carefully slide it out.
- With the front axle removed, loosen the fork clamp bolts located at the top and bottom of the fork tubes. These bolts secure the fork tubes to the triple clamp.
- Once the fork clamp bolts are loosened, gently slide the forks out of the triple clamp. It may be helpful to have an extra set of hands to support the weight of the forks.
- Once the forks are free from the triple clamp, carefully lower them to the ground or a soft surface to prevent any damage.
- With the forks removed, you can now proceed with changing the Ohlins fork seals.
Remember to handle the forks with care to avoid any scratches or damage. Always refer to the manufacturer’s instructions or consult a professional if you are unsure about any of the steps involved in removing the forks from your specific bike model.
Disassembling and Replacing the Fork Seals
When it comes to maintaining your Ohlins forks, it’s important to regularly inspect and replace the fork seals. Over time, fork seals can wear out or become damaged, leading to oil leaks and reduced suspension performance. In this guide, we’ll walk you through the process of disassembling your Ohlins forks and replacing the fork seals.
Tools and Materials Needed:
- Socket wrench
- Hex socket set
- Fork cap wrench
- Fork oil
- Fork seal driver
- Fork oil level gauge
- Fork seal cleaning tool
- Fork spring compressor
- Fork seal bullet tool
Step 1: Remove the Front Wheel and Loosen the Forks
Begin by securing your motorcycle on a stand or lift to ensure stability. Remove the front wheel to gain access to the forks. Loosen the fork pinch bolts using a socket wrench.
Step 2: Remove the Forks
Using a hex socket set, loosen and remove the upper and lower triple clamp bolts. Carefully slide the forks out of the triple clamp and set them aside on a clean work surface.
Step 3: Disassemble the Forks
Using a hex socket set, remove the fork caps from the top of the forks. Be cautious as the forks may have residual pressure. Slowly decompress the forks by pumping them a few times. Once decompressed, carefully pour out the fork oil into a drain pan.
Next, remove the fork springs using a fork spring compressor. Once the springs are removed, use a fork seal cleaning tool to clean the fork tubes and remove any old oil or debris.
Step 4: Replace the Fork Seals
Using a fork seal bullet tool, carefully pry out the old fork seals from the fork tubes. Clean the fork tubes thoroughly with a fork seal cleaning tool.
Apply a thin layer of fork oil to the new fork seals, and then use a fork seal driver to install them into the fork tubes. Ensure the fork seals are seated properly and evenly.
Step 5: Reassemble the Forks
Reinstall the fork springs using a fork spring compressor. Slowly pour the correct amount of fork oil into each fork tube, as specified by the manufacturer. Use a fork oil level gauge to achieve the correct oil level.
Reinstall the fork caps onto the top of the forks and tighten them securely with a fork cap wrench. Insert the forks back into the triple clamp and tighten the upper and lower triple clamp bolts with a hex socket set.
Step 6: Reinstall the Front Wheel and Test
Reinstall the front wheel and tighten the fork pinch bolts. Double-check all the bolts and make sure everything is properly tightened. Finally, take your motorcycle for a test ride to ensure the fork seals are functioning correctly and there are no leaks.
| Step | Description |
|---|---|
| 1 | Remove the Front Wheel and Loosen the Forks |
| 2 | Remove the Forks |
| 3 | Disassemble the Forks |
| 4 | Replace the Fork Seals |
| 5 | Reassemble the Forks |
| 6 | Reinstall the Front Wheel and Test |
Reassembling the Forks and Installing them back on the Bike
Once you have successfully changed the Öhlins fork seals, it’s time to reassemble the forks and install them back on your bike. Follow these steps:
- Clean and lubricate the inside of the fork tubes: Before reassembling, make sure the inside of the fork tubes is clean and free of any dirt or debris. Use a clean rag and some fork oil to wipe down the inside of the tubes, ensuring they are smooth and ready for reassembly.
- Insert the new fork seals: Take the new Öhlins fork seals and carefully insert them into the fork tubes. Make sure they are properly aligned and seated securely, as this will help prevent any oil leaks.
- Install the fork bushings and spacers: Once the fork seals are in place, it’s time to install the fork bushings and spacers. Slide them over the fork tubes and ensure they are arranged in the correct order as specified by the manufacturer.
- Reinstall the rebound and compression dampers: Next, reinsert the rebound and compression dampers into the fork tubes. These components are essential for controlling the fork’s performance and should be installed according to the manufacturer’s instructions.
- Assemble the fork legs: Carefully bring the fork legs together, aligning the fork tubes and the lower leg. Slowly slide the fork tubes into the lower leg until they are fully seated. Ensure the fork tubes are parallel and straight.
- Tighten the fork leg bolts: Use a torque wrench to tighten the fork leg bolts to the manufacturer’s specifications. This will ensure the fork legs are securely fastened and will prevent any potential issues while riding.
- Test and adjust the fork: With the forks reassembled, it’s important to test and adjust their performance. Make sure the rebound and compression settings are properly adjusted and that the forks are functioning correctly. Take your bike for a test ride and make any necessary adjustments according to your preferences.
- Securely mount the forks back on the bike: Finally, carefully mount the forks back onto your bike’s frame. Ensure they are securely fastened and aligned correctly. Use the appropriate tools to tighten the fork bolts and triple clamp.
With the forks properly reassembled and installed back on your bike, you can now enjoy a smooth and responsive ride thanks to the new Öhlins fork seals.
