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Discussion Starter · #1 ·
1980 SR250, my wife's bike, and my first attempt at replacing fork seals. I've got the forks apart but can't get the oil seals to move.

Just to recap what I've done:
- bike on jack, removed wheel and axle
- drained the forks
- removed circlips, top caps and springs
- removed bottom damper bolt

At this point, the 2 tubes come apart. I've read where some forks will not come apart and you can use the 2 tubes as a slide hammer to drive the seals out but that's not the case with these (unless I'm doing something wrong).

I removed the dust seal and retainer spring to expose the oil seal. I then used a bent fork type tool to grab the back edge of the seal and try to pry it out. No movement at all. I tried popping the handle of the tool with a hammer while I was prying, but all that did was to put some nice tool marks in the soft aluminum of the fork slider. I'll need to clean these up once I get the oil seal out. I've hit it with the heat gun up to the point that the rubber seal was smoking pretty good. I tried running a drywall screw into the side of the seal so I could pull on it. No luck. Right now I've got it soaking in PB Blaster to see if that helps. Any suggestions?

Thanks in advance,
Steve
 

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Discussion Starter · #3 ·
Success! Asked my neighbor for a hand (he's been around the block a few more times than I). We ended up cutting/pulling the rubber off the old seals down to the steel rings, and were then able to pry the seal frames out. Cleaned up any marks/scratches and reassembled the forks. I need to pick up some oil and a metric measuring cup tomorrow so I can button it up and give it a test ride.
 

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Discussion Starter · #4 ·
Located this service manual link using google... I did not download, nor read it, but perhaps there is a step you are missing?

http://www.manualedereparatie.info/en/download/yamaha-sr-250-Service-manual.html
Thank you fine sir. I actually downloaded that manual when I first bought the bike and had scoured it pretty thoroughly. Unfortunately, it's incomplete and it only covers replacing fork oil, nothing on replacing seals. Fortunately, I've got a great neighbor. Not only has he helped me out of many jams, he's a Goldwing owner since 1975 and he's the one responsible for my wife and I getting back into riding.
 
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