650 Forks, How do I....

[G0FHM]

Get them apart?

The seals are long dead, and on top of the seal in the tube some previous graduate of the Jeremy Clarkson School of Engineering has gone and packed some kind of fibrous material in....

But the best bit is the forks are full of oil/water mix! I was hoping to drain the remnants of the old oil out, and fill with fresh and install new seals - but now it's full of an olive green mush, the lot has to come apart and be checked/degreased.

I have the GS650G manual here, but that has air forks and the forks look totally different to the Kat (I don't think you have to use a hex T Bar to undo the damper rod on the GX). I've got the snap rings out on top of the seals - now what?

Thanks,

J

[waltfen]

Undo the hex nuts at the bottom of the forks, place the bottom legs in a vice (with protection) and slide the uppers out. They may be difficult to remove and you have to use the uppers like a slide hammer but they will come out and bring the seals, bushes etc. out with them.
To rebuild you have to put the sliders in before the seals.

[G0FHM]

Hi,

Hex nut at the bottom? I have a 6mm bolt at the bottom of each unit, I assume as an oil drain - which are already out.

Or do you mean the hex nut at the top of the fork, round the adjuster rod?

Unless I'm missing something at the bottom?

Thanks,

J

[fossie]

Follow the manual ,they are the same as the 650 gt but not the 650 L .
Only difference is the anti dive if fitted but that has no relevance to the fork seals.

[G0FHM]

The manual I have is for the GS650 G and GL - It's kind of confusing as according to that you need to insert a hex T key down the top to unscrew the damper rod, but the Kat has an adjuster poking out the top! In the top of the forks in this manual, the air valve screws in where my adjuster pokes out!

I'll have to try find another manual online that doesn't have air forks!

J

[fossie]

Once you take the top cap off with adjuster the forks are the same and yes you needs loooooong hex key, to hold the top of the Allen bolt that you can see and undo underneath.

[sparki]

or if you have an air gun you may get away without the looooooooooooooong key. think a 17 (across flats) nut on the end of a bit of threaded bar will do the same think

[G0FHM]

Cheers chaps....

Looks like i have my work cut out for me!

J

[sparki]

challenge

[G0FHM]

I don't like challenges

Gonna have to be done though