How to replace fork seals on my Voyager 1200

[Saddle up]

my Voyager is leaking much fork oil just sitting still, are the seals difficult to replace or should it be left to a shop.

[Nails]

I suggest trying seal savers (search here). If that doesn't work, order the seals, all bushings, and Progressive springs, and just take it to a shop.

I'm a fan of Dextron for fork oil (search here).

Mine only had 20k, but I'm glad for new bushings. Check your forks for scratches that could screw with the seals.

I do pretty-much all my own wrenching, and I had replaced the fork oil already. I removed the forks and took them and parts to a shop. I think this job is better left for the folks properly set up for it. Support your local independent shop.

I recommend minimizing the fork air system volume by attaching a Schrader valve to the manifold, where you can periodically bleed any pressure. I think you can then decrease the oil volume back to factory specs (research here).

And you.might consider installing fork boots.

[doug of so fla]

First buy SEALMATE Tool Google it. about $5.00 ea. simple to use you just run it around your shock tube while it is still on M/C and it will clear out any crap that may be causing the seal to leak .

How many miles on shocks?? if you do not know and the SEALMATE doesn't work. or if over 25,000 mi on shocks, get new bushings and dust seal and oil seals and IF you can get a hold of the proper seal driver and put in proper amt of shock fluid at the proper wt, It is fairly simple for a DIY guy or take the shocks off and bring to a Kaw tech or shock tech and have them rebuild them make sure you know what kind of a ride you want out of them. The wt of the oil and the type of springs you use will get the ride you want for your body weight. There are shock experts out there to help you: Traxxion , RaceTec, Proggressive, They have the parts and advice you will need. I would recommend Traxxion Dynamics in Ga. they will give you the information you need or you can send your shocks to them and they will rebuild them just for your riding style. many videos on you tube also..

Incidentally: If you have original shock fluid and internals, no mater how many miles or how long it has been in there it is ALL junk and should be rebuilt with all new items. OEM parts is best way to go..

EST $ cost of items:
SEALMATE $5.00
New springs $ 130.00
New bushings & seal kits $100.00
LABOR & FRT ??
New fluid, qt $15.00 ( Golden Spectro) +++ Good luck with it, Do it the right way and it will be more than worth it!!! RIDE SAFE!!!!

[Nails]

First buy SEALMATE Tool

If you don't want to wait, go buy some salad mix, the kind that comes in the clear plastic box that's stiff and thin. Still $5, but it's good for you. Cut a hook shape in the plastic -- doesn't have to be totally flat. And then do the deed.

[tnpete]

It may just have been me. But also let the air out of the forks. If not it will push out oil when you try to clean them. As for making your own seal cleaner. I use a cheap sheet of clear chopping board. I get them 2 per pack for $1. at the Dollar Tree.
Print out the copy of the deal I found online. Marked it out and within 2 minutes I had 2 made. And enough material to make a dozen more easy.

[Barry]

Did you take your bike to a shop to fix the fork seals, or follow the above suggestions? My vxii is 33 years old and is still leak free with the original seals. I attribute this to using gator covers which keeps the dirt & bugs from getting to the seals.

[Van Voyager]

Rebuilding the forks is a pretty easy job - the biggest difficulty is typically getting the damping rod bolt out of the bottom of the fork - an impact gun and a broom handle can help with that. Use an appropriate sized piece of PVC pipe as a seal driver, with the original seals (upside down) on top of the new seals as a driver buffer



Bushings don't wear out from age, they wear out from use. So depending on the mileage, and how often the fork oil was changed, the existing bushings may still be fine. I'd order a set to have on hand but if they're not worn (and it'll be obvious if they are), they don't need to be changed.