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Premium Member
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Discussion Starter #1
Did my first ever fork removal and teardown today, after a week of studying and driving people nuts with questions (the exploded view in the Clymers showing all those dam parts is pretty interesting). Like everything else the first is the worst, so the first tube from removal to re-install took about 2 hours. Turns out the cap and it's clip I've read so much about was pretty dam easy; I've got that part down to a science and probably 2 minutes max to R & R.

When I took the first tube apart to pull it apart, that old seal was really attached in there, so I struggled with that for a while and when it finally did let go, parts went flying, and so did the "verbage". :doh: (my wife came running out of the house thinking I was hurt LOL)

Finally got it all reassembled and then had fits getting the correct amount of fluid in it, that part alone took me about 40 minutes. (Freakin OCD is like an anchor sometimes)

I learned alot from the first tube though, so then the other tube took about 45 minutes from removal to installing and that included breaking an allen wrench, and throwing some more metaphors around. :doh:

All in all though, not a bad job, and a good thing too, because that old fluid and those seals were every bit of 20 years old (OEM) and needed help bad, and man does the front end feel better now, from just a simple fluid change. (took the majority advice here and went with the Bel-Ray 15W)

The feel through the bars is better, and more firm, and alot less diving under braking. :smiley_th

It's cool when you do some work on the bike and besides the peace of mind, you can actually feel some improvement IMO, and for all of you I pestered via PM, thanks for taking the time, it helped me alot get through the first one.
 

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Linkmeister Supreme
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Good going Doug. I bet mine are in the same condition. I`ll probably be pestering you for advice in a couple of months.
 

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The Professor
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Did my first ever fork removal and teardown today, after a week of studying and driving people nuts with questions (the exploded view in the Clymers showing all those dam parts is pretty interesting). Like everything else the first is the worst, so the first tube from removal to re-install took about 2 hours. Turns out the cap and it's clip I've read so much about was pretty dam easy; I've got that part down to a science and probably 2 minutes max to R & R.

When I took the first tube apart to pull it apart, that old seal was really attached in there, so I struggled with that for a while and when it finally did let go, parts went flying, and so did the "verbage". :doh: (my wife came running out of the house thinking I was hurt LOL)

Finally got it all reassembled and then had fits getting the correct amount of fluid in it, that part alone took me about 40 minutes. (Freakin OCD is like an anchor sometimes)

I learned alot from the first tube though, so then the other tube took about 45 minutes from removal to installing and that included breaking an allen wrench, and throwing some more metaphors around. :doh:

All in all though, not a bad job, and a good thing too, because that old fluid and those seals were every bit of 20 years old (OEM) and needed help bad, and man does the front end feel better now, from just a simple fluid change. (took the majority advice here and went with the Bel-Ray 15W)

The feel through the bars is better, and more firm, and alot less diving under braking. :smiley_th

It's cool when you do some work on the bike and besides the peace of mind, you can actually feel some improvement IMO, and for all of you I pestered via PM, thanks for taking the time, it helped me alot get through the first one.
I feel you pain or at least I will be feeling your pain. I have Known for quite some time this day would come. My left fork seal went from very slight moisture to I frikin give up! Seals will be here monday and I am sure the foul language will soon follow. LOL :doh:

I still have not decided on 10w or 15w oil, I changed my oil in 01' before the complete rebuild and have since lost too many brain cells to rember what oil I used. :doh:

As with you I had no problem removing the retainer clip, I did mine on the bike.

I am sure after 24 years these seals will put up a fight!!!

Since all of the horrer stories of flying parts I will wrap with plastic and tape the ends before I seperate the slider. :beerchug:

I will post results soon.
 

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Premium Member
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Discussion Starter #5
Yeah Lance, I hear you. One of my dust seals was just wiped out, and let water into the oil seal area. The oil seal, and it's retainer ring wear pretty well corroded into the fork tube, so it took alot of effort to separate and that's part of how I ended up flinging parts; I had to pull on the tube so hard that when they separated they came very far apart when the seal finally let go.

The second tube I laid a big towel over everything so the parts wouldn't fling, and saved a bunch of time right there.

As far as the fluid goes, in the Verses, somebody wrote up which fluid works best for rider weight, so I went by that. (15W if your 185lbs or more) and then just used the Bel-Ray because it's the most talked about around here.

I think I might just change me fluid again at the end of summer after letting this stuff rinse away any thing I may have missed, as changing the fluid can be done without any drama.
 

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My right seal is weeping a bit, was thinking of replacing them over the winter, but never got around to it. Now that it riding season I don't want to have to disassembly to see what needs to be replaced and wait to order new parts.

Is there a list of parts that should be replaced?
 

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The Professor
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3,147 Posts
My right seal is weeping a bit, was thinking of replacing them over the winter, but never got around to it. Now that it riding season I don't want to have to disassembly to see what needs to be replaced and wait to order new parts.

Is there a list of parts that should be replaced?
Fork seals, dust seals, upper retaining ring and fork oil.You can get from Ma Kaw or the link below. :smiley_th

SEALS

http://cgi.ebay.com/ebaymotors/Kawasaki-VN750-Vulcan-84-02-Fork-Seals-Dust-Seal-Set_W0QQcmdZViewItemQQ_trkparmsZ66Q3a2Q7c65Q3a1Q7c39Q3a1Q7c240Q3a1318QQ_trksidZp3911Q2ec0Q2em14QQhashZitem120394068787QQitemZ120394068787QQptZMotorcyclesQ5fPartsQ5fAccessories

OIL

http://cgi.ebay.com/ebaymotors/Motorex-15W-Fork-Oil_W0QQcmdZViewItemQQhashZitem180330573533QQitemZ180330573533QQptZMotorcyclesQ5fPartsQ5fAccessories

SNAP RING #92033-1201
 

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Linkmeister Supreme
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The Professor
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They work now. :smiley_th
 

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363 Posts
doug , i might have to let you show me how to do the fork seals one weekend in may . i will have to see how the money situation is in may . i will let you know when me meet up some time soon. allways like to have someone looking over my shoulder when i am doing something i havent done before, never know what questions i might have .
 

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Premium Member
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Discussion Starter #11
I'd be happy to come out and give you a hand when you're ready, just say the word. It would definitely make the first time less intimidating. I was alone other than my always supportive wife, (she tries like hell), and a couple friends from here via PM.

I bought all my stuff from Bike Bandit and got it all at once, except the fluid. I bought some spare swing arm caps and a volt meter too, but IIRC the seals weren't too costly, but by all means shop around. The fluid can be bought locally at any bike shop for the same price as found online if you're out and about.

Anyway, just let me know if and when. ;)
 
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