I just bought new fork seals for my 85 350X . I dont know where to start to replace them , or what exactly needs to be done . Can some eone tell me exactly what I need to do . Thanks in advance !!

 

I have to replace my seals also. I have not attempted the replacement yet but do not anticipate too many problems. Remove the allen screw at the bottom of the fork. Next, notice the top cap screw. Secure the fork in a soft vise (don't want to mare the surface) and unscrew the cap. Be careful the springs are under pressure. Remove the upper spring, spring seat and the lower spring. Next, pour the fork oil out and pump the fork several times to expel any remaining oil. The remaining steps are pretty straight forward. Just remember the order in which you removed all the pieces.

It may help to get a repair manual, Clymer has a good book that I use. It explains every step in detail with a parts view of every piece and the order in which they go. Check it out if you are unsure.

 

I wonder if there is also a clip that is hidden under the fork boots? I think it might be right where the bottom of the boot goes over the bigger part of the shock. Mine are also worn out in my '86 350x.

'86 350x
'85 200x
2 '85 350x bare frames

 

It is easiest to jack up the wheeler so the shocks are fully extended, then unscrew the tops when they are still in the clamps. There is barely any spring pressure like this. Then remove the shocks from the triple clamp. Take springs out and the boots off, there is a circlip hiding in where the smaller shock tube goes into the larger bottom tube(its probly hidden with dirt). once you get it out you take the allen bolt out of the bottom. Put the larger tube in a vise and yank on the smaller tube. The seals are pressed in there. you may have to customize some of your tools with a grinder before you are done, but Its pretty easy. If you dont have a manual I can look up how much oil you need to put in. You shouldent overfill it or they will leak again.

 

two and a half years later - i'm doing the same, but the clymer manual isn't available in retail. its not in any catalog. so, my forks are off the bike and all the parts are out from inside. but whats the circlip? is it under the dust seal? how do i get to it? i hope you guys still get this thread.

-kevin