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Old 01-29-2010, 10:15 AM   #1 (permalink)
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do I need to remove the damping setup at the lower fork legs to replace seals? Manual did'nt seem specific about it to me. Or do I just remove the lower fork bolt and upper bolt and pop the inner legs out for the change. The bike is a 1989 1500. thanks
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Old 01-29-2010, 11:25 AM   #2 (permalink)
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No you do not have to remove the dampers. Remove the lower bolt and drain the oil, pull the dust seal up and remove the retaining ring and pop the lower off. There is a fork seal tutorial in the ref/faq forum, I think it's for a 1200 but they are all pretty much the same.
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Old 01-29-2010, 01:19 PM   #3 (permalink)
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DaveO430 wrote:
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No you do not have to remove the dampers. Remove the lower bolt and drain the oil, pull the dust seal up and remove the retaining ring and pop the lower off. There is a fork seal tutorial in the ref/faq forum, I think it's for a 1200 but they are all pretty much the same.
Nice to have you verify that about the damper. I always took that bolt out even when just changing the seals, never though about leaving it in.
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Old 01-29-2010, 01:30 PM   #4 (permalink)
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Now I'm confused, which other bolt are you referring to?
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Old 01-29-2010, 01:34 PM   #5 (permalink)
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DaveO430 wrote:
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Now I'm confused, which other bolt are you referring to?
The 6mm allen head bolt inside the axle mount area that holds the damper to the bottom of the lower fork tube.
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Old 01-29-2010, 01:42 PM   #6 (permalink)
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Yes that one has to be removed to get the fork apart, there is no other one there, that I know of.
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Old 01-30-2010, 09:05 PM   #7 (permalink)
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Not as bad as I thought. Its just all the junk you have to remove to get to the forks. Could have swapped the seals on my klr 1/2dozen times in the time it took to do this. I at least know I have progressive springs up front as well. Hope this helps out with the new seals. 1 leg had maybe 2oz of oil in it if that. Suspension should be alot better now. Thanks for the info folks
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Old 01-31-2010, 07:43 AM   #8 (permalink)
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h2smokin wrote:
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I at least know I have progressive springs up front as well.


Just to clarify for those that have never opened up, or removed the forksprings.

The earlierstock 1500 set-up is 2 springs per leg seperated with a large 'washer', with the longer one being progressively wound. Later years used a 'spacer' instead of the shorter spring on top

Also, check the length of the larger, main spring to make sure it is within service limits. If it measures 382.8mm/15.07" or less, - replace them

If you only have one spring per leg and no spacerin the 1500, then you most likely have a set of Progressives installed.

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