Fork Seal Change

[Aladinbama]

Is there a video anywhere that shows the specifics to the Voyager XII when changing the fork seals (retainers, clips and such)? I've changed them in other bikes and there always seems to be model specific stuff!
I've got a 2000 that the seals leaked and I need to change the fluid anyway. I've used the sealmate and a home made one a few times and it's still moist on the forks so I thought I would just change them. This was an Arizona bike that sat for some time.

[triton28]

The following assumes drained and removed fork tubes with the internal springs, and dust seals already removed:
once you overcome the blue Loctite, using a deep 6mm allen socket and an air impact tool, on the fork cylinder bolt at the bottom of the forks; and have removed the circlip holding the seal into the aluminium outer leg; then the fork tube can be used as a sliding hammer to remove the seal and bushings. It's pretty simple, albeit a bit messy when the tube comes out of the aluminium leg.
Just remember the double lip on the seal is down against the force of the oil, and don't use too much Loctite on the clean, dry cylinder bolt.
The hardest part is keeping the damper cylinder from rotating at reassembly. Some use a long sharpened hardwood dowel, others a 4 sided 1/2" drive wedge socket on extensions, but I find the air tool works the best. I always hand check it for torque after it stops tightening.
Oh yeah, the top plug holding the springs will move down away from the circlip easier if you give the plug a rap with a brass drift and a hammer to break it free of any corrosion holding it in.
Good time to install upgraded aftermarket springs if it doesn't have them.

[Aladinbama]

Good time to install upgraded aftermarket springs if it doesn't have them.

This takes out any air adjustment - correct?
I've seen some race-tec vs, progressive discussions, but do progressives improve the suspension that much? I tend to like things stock, but ....
In the past, on other bikes, a fork oil change was pretty much all that was necessary to stiffen things back up. This ones pretty spongy right now!

[Mr Jensee]

We just did the seal change on the Charlie Voyager I put up for sale. It wasn't hard. You will need to find a way to secure the bike upright without the forks or wheel on it. We used a chain hoist but you could use a small jack under the engine if you are careful A lift is best. Pull off the wheel and fender. Loosen the bolts on the top and bottom of the triple tree. You dont have to remove them. Gently pull down on each fork and reach up and remove with your hand the metal ring seal for the air. Pull the fork completely out. We used a piece of wood about 8 inches long where we drilled a hole in the middle and put in a bolt with a washer and nut through it. This formed a T with a handle with which we could push down on the center of the cap. This gave us something to push down on the top of the fork to get the cap and circlip out. push down on the cap about a half an inch and the clip will be exposed. You can remove it with your hand. We went to Harbor Freight and got a set of long allen wrenches with socket ends. This allowed me to use an impact driver to remove the bolts. Without one you will be spending half the day trying to remove the bolt. Once you have the bolt removed and the spring out and the old fluid drained you can just pull apart the fork tubes. Remember to remove the dust caps off the forks before you get started. I found the best way to seat the new seals is to take it to a Kawasaki shop and for $20 they pounded them in place. Carl Leo recommended putting a thin piece of plastic around the top of the fork so you can slide the new seal on without having it tear on the groove where the air seal was removed. The rest is straight forward like any fork seal replacement. There are tons of videos on YouTube to show you. I think I remember we put 140cc in each fork before we put back the spring. Just remember once assembled to pull the fork tube all the way up before you add your fluid. We used 10w Honda fork fluid.

To answer your questions about the Progressives. Yes they improve the suspension a lot. The bike will handle and track like a sport bike in curves when you have them. I also suggest replacing the back shocks with Progressives also.

[Aladinbama]

Thanks!

I bit and have springs ordered. They'll be here by next Friday. Now I guess I'll just read and watch!
I guess I could always start and be ready to have it together by Saturday
(I've got two others to ride though, so ...)