XR600 front fork seals

[Mick DMember]

Alright, tonight we go into the CAT630 as she has a leaking front fork among other things.
Has anyone replaced fork seals on a BRP?
If so, is there any tricks or things that I should look out for?

[Mick DMember]

Three hours, 50,000 expletives and close to a carton of piss and we got the seals in. You have to pull the bastards right apart to put the seals in!! Take it from me, get a workshop manual if you are thinking about doing it yourself, it is a tad tricky to say the least. I did a fair bit of chin scratching.
We manufactured a seal seating tool to replace the special one, the manual said you had to have but that is another story.
Also we didn’t realise that when you replace the seals it is a good idea to replace the dust seals at the same time as we stuffed one up getting it out and now we can’t bolt the forks back in until we get some new dust seals. I will be amazed if the local Honda dealer has them in stock….. Ah the joys of living in the bush.

[Brad BallingerMember]

Harden up Mick, I hope you never get a bike with twin chamber upside downers!!!!!!!!
Next time when the seals are leaking try running a 1.5 thou feeler gauge(or you can use 35mm film negative) up under the seal and running it around the seal. This usually dislodges any dirt under the seal. Also look for any nicks/dents in your chrome, or you may be replacing them again. Make sure you bleed the air out of you forks every ride(do it with forks fully extended, not sitting on bike as the will change your air gap in your forks. Therfore affecting fork action.

[Mick DMember]

I dont have to worry about real techie shit like that, as I know a guy who works for Westrac and he seems to know all about that stuff. Dont ya?
BTW the seal on the Cat XR was way past fixing with a feeler gauge. It was leaking like an Indonesian fishing boat.

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