If you own an AJS Bobber motorcycle, you may find yourself in need of replacing the fork seals at some point. The fork seals are an important component of the front suspension system, as they help to keep the oil inside the forks and prevent any leaks. Over time, the fork seals can wear out or get damaged, resulting in oil leakage and reduced performance.
Replacing the fork seals on your AJS Bobber is a fairly straightforward process, but it does require some basic mechanical knowledge and the right tools. In this article, we will guide you through the step-by-step process of changing the fork seals on your AJS Bobber, so you can get back on the road with a smoother ride.
Step 1: Lift the Front of the Motorcycle
Before you can start replacing the fork seals, you will need to lift the front of your AJS Bobber motorcycle off the ground. This can be done using a motorcycle lift or by placing a jack under the engine. Make sure the motorcycle is securely supported before proceeding with the next steps.
Step 2: Remove the Front Wheel and Forks
To access the fork seals, you will first need to remove the front wheel and forks. Start by loosening the axle nut and removing the axle. Then, loosen the pinch bolts on the triple clamps to release the forks. Carefully slide the forks out of the triple clamps and set them aside.
Step 3: Disassemble the Forks
Once the forks are removed, you can begin disassembling them to access the fork seals. Start by removing the fork caps, which are usually held in place by a bolt or a plug. Then, turn the forks upside down and let the oil drain out into a container. Next, remove the fork springs and the spacers.
Note: It is a good idea to replace the fork oil and dust seals while you have the forks apart, as they can also wear out over time.
Step 4: Remove the Old Fork Seals
With the forks disassembled, you can now remove the old fork seals. Use a seal pick or a small screwdriver to carefully pry the old seals out of the fork tubes. Be gentle to avoid scratching or damaging the fork tubes. Once the old seals are removed, clean the fork tubes thoroughly using a clean cloth or paper towels.
Step 5: Install the New Fork Seals
Now it’s time to install the new fork seals. Apply a thin layer of clean fork oil to the inner surface of the fork tubes to lubricate the seals. Then, carefully slide the new seals onto the fork tubes, making sure they are seated properly. You can use a seal driver or a piece of PVC piping to help you tap the seals into place.
Tip: It is recommended to use genuine AJS Bobber fork seals for the best fit and performance.
Step 6: Reassemble the Forks and Install
Once the new fork seals are in place, you can reassemble the forks. Start by reinserting the fork springs and the spacers. Then, refill the fork tubes with the recommended amount of fresh fork oil. Reinstall the fork caps and tighten them securely. Finally, slide the forks back into the triple clamps and tighten the pinch bolts.
Step 7: Reinstall the Front Wheel and Lower the Motorcycle
With the forks securely in place, you can now reinstall the front wheel. Slide the axle through the wheel and forks, and tighten the axle nut. Then, lower the motorcycle off the jack or lift, making sure it is stable and level.
By following these steps, you should be able to successfully change the fork seals on your AJS Bobber motorcycle. Remember to always consult your motorcycle’s owner’s manual for specific instructions and torque specifications. If you are not confident in your mechanical abilities, it is recommended to seek professional assistance.
Step-by-Step Guide: Changing Fork Seals on AJS Bobber
Changing the fork seals on your AJS Bobber is an important maintenance task that ensures your bike’s suspension performs at its best. Here is a step-by-step guide on how to do it:
Step 1: Gather the necessary tools and materials
Before you start, gather the following tools and materials:
- Fork seal kit
- Fork oil
- Socket wrench
- Allen keys
- Fork oil level gauge
- Fork spring compressor
- Shop rags
- Container for draining oil
Step 2: Prepare the bike
Park your AJS Bobber on a stable surface and make sure it is secure. To access the fork seals, you may need to remove certain parts, such as the front wheel, brake caliper, and possibly the front fender. Refer to your bike’s manual for specific instructions.
Step 3: Drain the fork oil
Using a socket wrench, remove the drain plug located at the bottom of each fork leg. Place a container underneath to catch the oil. Let the fork oil drain completely.
Step 4: Remove the fork legs
Take off the fork clamps or bolts that secure the fork legs to the triple trees. Gently slide the fork legs out of the triple trees and remove them from the bike.
Step 5: Disassemble the fork legs
Using the appropriate tools, carefully disassemble the fork legs. This may involve removing the compression adjuster, rebound adjuster, and any other components specific to your AJS Bobber’s fork design. Take note of the order and placement of each part.
Step 6: Replace the fork seals
Remove the old fork seals and clean the seal seats. Install the new fork seals according to the instructions provided in the fork seal kit. Be gentle to avoid damaging the new seals.
Step 7: Reassemble the fork legs
Reverse the disassembly process to reassemble the fork legs. Make sure all components are properly aligned and tightened to the manufacturer’s specifications. Refer to your bike’s manual for torque values.
Step 8: Refill with fork oil
Using a funnel, pour the recommended amount of fork oil into each fork leg. Refer to your bike’s manual for the correct oil weight and volume. Use a fork oil level gauge to ensure the proper oil level.
Step 9: Reinstall the fork legs
Slide the reassembled fork legs back into the triple trees and secure them with the fork clamps or bolts. Make sure they are properly aligned and tightened.
Step 10: Test and adjust
With the fork legs back in place, install any removed parts, such as the front wheel, brake caliper, and front fender. Test the suspension by compressing and rebounding the forks. Check for leaks and make any necessary adjustments.
By following these steps, you can successfully change the fork seals on your AJS Bobber and maintain optimal suspension performance. Remember to consult your bike’s manual for specific instructions and torque values.
Preparing for the Job
Before you start changing the fork seals on your AJS Bobber, it’s important to gather all the necessary tools and materials.
Tools
- Socket set
- Torque wrench
- Spanner set
- Screwdriver set
- Rubber mallet
- Plastic baggies
- Shop towels
Materials
- New fork seals
- Fork oil
Once you have all the tools and materials ready, you should prepare your workspace. Find a flat and well-ventilated area where you can work comfortably without any distractions.
It is also a good idea to read the AJS Bobber owner’s manual or any specific instructions provided by the manufacturer for changing fork seals. This will give you a better understanding of the process and any model-specific details you need to be aware of.
Before starting the job, make sure you have enough time to complete it without rushing. Changing fork seals can be a time-consuming task, especially if you encounter any unexpected challenges along the way.
Lastly, it’s a good idea to have a clean and organized workspace. Clear away any clutter and have all the tools and materials easily accessible. This will make the process smoother and more efficient.
Removing the Forks from the Bobber
To replace the fork seals on your AJS Bobber, you will first need to remove the forks from the motorcycle. This process can be broken down into several steps:
1. Secure the Bike:
Park the Bobber on a level surface and engage the front brake to keep it from rolling. Additionally, if you have a center stand or a paddock stand, it can provide extra stability during the removal process.
2. Loosen the Triple Clamps:
Using a suitable wrench or socket, loosen the bolts that secure the triple clamps to the frame. These bolts are usually located at the top and bottom of the triple clamps on each side.
Note: Be cautious when loosening the lower triple clamp bolts, as they may be under tension from the front wheel axle.
3. Remove the Front Wheel:
If necessary, use a suitable jack or stand to elevate the Bobber’s front end, and then remove the front wheel by loosening the axle nut and sliding the axle out. Gently lower the motorcycle back down once the wheel is removed.
4. Disconnect the Forks:
Locate the fork tube pinch bolts on the triple clamps and loosen them using an appropriate wrench or socket. Once the pinch bolts are loosened, the forks can be gently pulled out of the triple clamps.
Note: Make sure to support the weight of the forks as you remove them to prevent any damage or injury.
5. Remove the Forks:
With the forks disconnected from the triple clamps, carefully slide them out from the fork tube holders. Be mindful of any wires or cables that may be attached to the forks and ensure they are properly disconnected before completely removing the forks.
Now that you have successfully removed the forks from your AJS Bobber, you can proceed with replacing the fork seals. Make sure to follow the manufacturer’s guidelines and use the appropriate tools and techniques for the job.
Disassembling and Replacing the Fork Seals
If you’ve noticed leaking fork seals on your AJS Bobber, it’s essential to replace them to maintain proper suspension performance. Here’s a step-by-step guide on how to disassemble and replace the fork seals:
1. Preparation
Before starting the disassembly process, make sure you have the necessary tools and supplies:
- Socket set
- Wrench
- Fork seal driver
- Fork oil
- Shop rags
Having everything ready will help streamline the process.
2. Front Wheel Removal
Caution: Ensure the bike is properly secured before lifting the front wheel off the ground.
Begin by loosening the front axle pinch bolts and removing the axle nut. Gently drop the front wheel down and roll it out. This step will provide easier access to the fork seals.
3. Fork Tube Removal
Caution: Take extra care when handling the fork tubes as they are delicate components.
Use the socket set and wrench to loosen the triple clamp bolts that secure the fork tubes. Once loosened, slide the fork tubes out of the triple clamps. Take caution not to damage the fork tubes or any other parts during this process.
4. Disassembling the Fork Tubes
Caution: Wear gloves to protect your hands from sharp edges and prevent fork oil spillage.
With the fork tubes removed, carefully dump out any remaining fork oil and compress the forks to release the internal pressure. Next, locate the fork cap at the top of the fork tube. Remove the fork cap using the appropriate socket or wrench. Now, carefully slide the fork tube apart, separating the upper and lower sections.
5. Removing the Old Fork Seals
Once the fork tubes are disassembled, use a fork seal driver to carefully pry out the old fork seals. Take care not to scratch or damage the fork tubes during this process. Inspect the fork tubes for any signs of damage or wear that may have caused the leaky seals.
6. Installing the New Fork Seals
Apply a thin layer of fork oil to the new fork seals, ensuring they are lubricated. Slide the new fork seals onto the fork tubes, making sure they are positioned correctly. Use the fork seal driver to gently tap the seals into place, ensuring they are properly seated.
7. Reassembling the Fork Tubes
Carefully reassemble the fork tubes by aligning the upper and lower sections. Make sure the fork tubes are properly aligned and slide them together until they are fully seated. Reinstall the fork cap and tighten it using the appropriate socket or wrench.
8. Reinstalling the Fork Tubes and Front Wheel
Slide the fork tubes back into the triple clamps and tighten the triple clamp bolts securely. Reattach the front wheel by sliding the axle through the forks and tightening the axle nut. Finish by tightening the front axle pinch bolts.
After completing the above steps, you should have successfully disassembled and replaced the fork seals on your AJS Bobber. Remember to refill the fork tubes with the appropriate amount and type of fork oil according to your bike’s specifications. Finally, test your bike to ensure the fork seals are no longer leaking and that the suspension is functioning correctly.
Reinstalling the Forks and Testing
Once you have successfully replaced the fork seals on your AJS Bobber, it’s time to reinstall the forks and test their functionality.
1. Start by aligning the fork tubes with the triple tree and sliding them back into place. Make sure that the fork tubes are properly seated and the top caps are secured.
2. Tighten the fork tube pinch bolts to the manufacturer’s recommended torque settings. This will ensure that the forks are securely held in place.
3. Reinstall the front wheel, making sure it is properly aligned with the forks. Tighten the axle nut to the recommended torque settings.
4. Double-check all the bolts and connections to ensure everything is properly tightened and installed.
5. Once the forks are reinstalled, it’s time to test them for leaks and proper functioning. Slowly pump the forks up and down a few times to check for any unusual resistance or noises.
6. Take your bike for a short test ride, paying attention to how the forks feel during braking, acceleration, and turning. If you notice any abnormalities or issues with the forks, address them before continuing to ride.
By following these steps, you should be able to successfully reinstall the forks on your AJS Bobber after replacing the fork seals. It’s important to regularly maintain and inspect your forks to ensure optimal performance and safety while riding.
