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  #1  
Old 08-09-2007, 09:38 PM
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Default taking my yz125 forks apart

     

its an 02 and ive never changed fork seals before...i know how to change springs and all that but ive never taken a fork completely apart so i cant get to the seals...anyone got a how to on it?
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  #2  
Old 08-09-2007, 11:03 PM
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Default Re: taking my yz125 forks apart

If they are the same (or similar) to my 01 yz250 forks then you will need a special tool to do the job. I made one out of an old jack handle, rocky mountain used to sell them for $70.
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  #3  
Old 08-09-2007, 11:59 PM
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Default Re: taking my yz125 forks apart

got any pics of what the tool looks like? or the one you made?
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  #4  
Old 08-10-2007, 03:25 AM
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Cool Re: taking my yz125 forks apart

it is pretty straight foward to strip the fork (i did on my 02 yz125 before)

job will be easier if you got a air wrench, if not it doesn't matter, just need abit of luck and more energy

with the fork out of triple clamp, before you start any work, back out all compression and rebound clicker, make a note and count them.


1. loosen fork cap, loosen the jam nut and fork cap can be taken out, and you can remove at this juncture, and collaspe the fork tube

2. pour out all the fork oil into a container

3. with the air wrench, and correct size allen (a quality type), spin out the base valve out from under the fork leg, base valve should spin out relatively easy

4. with the base valve out, the cartridge can be pull out of the fork

5. now, you can start to split the fork tube

6. pry open the duct cover with a large screw driver

7. use a small screw driver to remove the clip inside

8. with the clip remove, hold the fork tube, 1 hand on the chrome part, 1 hand on the other fork tube, with a swift jerk action, pull apart the fork tube

9. from here, you can seethe seal, 2nos teflon coated bushing, remove them

10. with the correct order, slip the duct cover down the chrome tube, follow by clip, seal (before it can cut the seal), the outer bushing, and lastly the inner bushing

11. slip the chrome tube into the other fork leg, let the inner bushing in and then the outer bushing, use a fork seal rammer to knock it lightly into the fork tube, it should seat it easily

12. now, use the fork seal rammer and seat the seal in snugly (not to much strength), just make sure it seat down squarely

13. put back the clip, and duct cover (you can use the seal rammer)

14. now you are done, with seal replacement

15. collaspe the fork tube, make sure the fork tube are sliding in and out effortlessly

16. then slid back in the cartridge, and use ya hand to screw back the base valve slowly, when it is hadn tight, use the air wrench to tighten it, and then a torque wrench to it suggested torque number

17. now, pour in ya favourite fork oil and bleed it properly (this is important)

18. with the correct oil height, slip in the fork spring and install the fork cap

19. set all clickers back to original setting and you are ready to go.

hope this helps.
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Old 08-10-2007, 11:05 AM
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Default Re: taking my yz125 forks apart

yea that helps thanks
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Old 08-10-2007, 11:15 AM
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Default Re: taking my yz125 forks apart

Bob,
I am glad someone else wrote all that out for you. Two things you may encounter: If you don't have an air wrench I loosen the allen head when the fork is still on the bike. Just crack it loose at that point. I can get them loose by hand easier if there is some spring load on the tubes. Sometimes lots of spring load via a tie down strap.

Second is the "jerk". Sometimes it takes a whole lot of that action to get the forks apart. You are actually pulling the bushings out as you do this. It takes more force sometimes than you think it should, but is is the only way to get them apart.


You can make some useable drivers from PVC pipe, or better those PCV pipe connectors that glue on. A blade, a file, a heat gun, you can get them to fit. (hose clamps too).
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Old 08-10-2007, 11:05 PM
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Default Re: taking my yz125 forks apart

oh ya, i left out the "if ya do not have the air wrench part"

what i do is, clamp the fork leg onto a aluminium vice firmly
with 1 hand pulling down (compressing) the fork, the other hand, loosen the basevalve.

it will be easier if ya got a buddy with ya.

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Old 08-11-2007, 05:35 AM
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Default Re: taking my yz125 forks apart

me and a friend of mine changed mine and his last night...wasnt no where near as hard as i thought it would be...we didnt have a seal driver but we still go them in there...it would have been easier with one tho.
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Old 08-11-2007, 11:56 AM
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Default Re: taking my yz125 forks apart

I think all the guy wants to do is change the seals in his forks. Why are many of you steering him into special tools and a complete rebuild like removing the base valve?

YOU DO NOT HAVE TO GO THIS FAR TO REPLACE SEALS!!!

The only tools he needs are a couple wrenches, a small screwdriver or pick to remove the internal snap ring found under the dust seal, and a seal driver which can be made from a piece of PVC pipe. A seal sleeve helps but can be done without.

Simply tear the forks down, per the manual, only until you have the two sections apart. DONT GO ANY FURTHER! Everything can be done from there. Then find a piece of PVC pipe that will fit over the inner tube and inside the outer tube. Cut it about two or so inches long and than down each side so you have two halves. Use it do drive the primary seal.

Sorry, but thats all folks. Easy!

Head Banger

Last edited by Headbanger; 08-11-2007 at 12:24 PM.
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Old 08-11-2007, 02:48 PM
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Default Re: taking my yz125 forks apart

Quote:
Originally Posted by Headbanger View Post
I think all the guy wants to do is change the seals in his forks. Why are many of you steering him into special tools and a complete rebuild like removing the base valve?

YOU DO NOT HAVE TO GO THIS FAR TO REPLACE SEALS!!!

The only tools he needs are a couple wrenches, a small screwdriver or pick to remove the internal snap ring found under the dust seal, and a seal driver which can be made from a piece of PVC pipe. A seal sleeve helps but can be done without.

Simply tear the forks down, per the manual, only until you have the two sections apart. DONT GO ANY FURTHER! Everything can be done from there. Then find a piece of PVC pipe that will fit over the inner tube and inside the outer tube. Cut it about two or so inches long and than down each side so you have two halves. Use it do drive the primary seal.

Sorry, but thats all folks. Easy!

Head Banger
yea all i was wanting to do was change seals...got it done last night tho...wasnt near as bad as i thought it would be
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  #11  
Old 08-12-2007, 08:20 AM
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Default Re: taking my yz125 forks apart

opps, perhap i have over-reacted

anyway, i thought it will be good to change the fork oil at the same time..

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  #12  
Old 08-12-2007, 04:36 PM
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Default Re: taking my yz125 forks apart

Too much information for someone like me is better than too little. I tend to like to take them all the way down, as I firmly believe that the dirt that went passed the seals, (ruining them) is inside RUINING something else.

So no, I WOULD NOT have considered the shortcut suggested. If the original poster had asked how to change a piston, I don't think anyone would have wanted him to receive the shortcut on that one. I think of suspension units which cost a good deal more to replace than a piston or cylinder does (with new or like new anyway) as something to do RIGHT.

But I guess HB is right, he did just want to change the seals.

Good tutorial nonetheless. Present the info and let the user decide which steps he would like to skip.
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  #13  
Old 08-15-2007, 03:34 AM
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Default Re: taking my yz125 forks apart

any problem just post back up here.

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  #14  
Old 08-29-2007, 02:00 PM
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Default Re: taking my yz125 forks apart

is this the same process for, say a '97 CR 125? i was out riding some trails today and i noticed my front fork leaking oil. im by no means an expert in bike repair nor do i have any manuals, so if someone could help me out that would be great. thanks
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  #15  
Old 08-29-2007, 08:29 PM
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Default Re: taking my yz125 forks apart

if my memory does'nt fail me

this is the same 46mm USD fork, with identical internal parts (differernt valve stack of course)
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