[rtillery02]

FORK SEALS
First time to renew my fork seals on  my 2002 Iron Barrel 500.
What , if any special tools do I need for this job to make it easier & right?
I'd like to do the job only once @ a time.Thanks for any input, R.Tillery

[Boxerman]

This any help?
http://tiny.cc/t4lgjz

Frank

[Enfield Pro]

Do you have new seals already?

[Arizoni]

If you try to pry the old seals out of the fork tubes, take special care when you do it.

The aluminum alloy they made the fork tubes out of is especially brittle and if you apply too much force in any one place, it can break the aluminum tube.  In other words, go slowly and gently.

[Seipgam]

I followed the Hitchcocks guide which Frank has provided the link to, all pretty straight forward. None of the "special tools" are required.
Mine originally had only one seal in each leg, but now has two.

As pointed out, be careful with side leverage when removing the old seals.
I made up a simple nut and bolt arrangement that lifted the seal out with no side leverage. 
Let me know if you want a diagram of what I made up.

Cheers, Geoff.

[Paul W]

In the past I've removed tightly fitting oil seals by drilling into their rim and inserting a self tapping screw in the hole, to pull against.

If you drilled two diametrically opposite holes and inserted screws through two holes in a steel bar cross piece ("bridging" the gap), you could drill a central hole in the cross piece and insert a length of threaded rod with nuts and washers to make into a simple slide hammer. This would mean no need for any "levering"; the seal would pull straight up and out.

[Boxerman]

In the past I've removed tightly fitting oil seals by drilling into their rim and inserting a self tapping screw in the hole, to pull against.

I've used a similar method but used a masonry nail to punch the hole, rather than a drill which makes swarf.

Frank

[Paul W]

I've used a similar method but used a masonry nail to punch the hole, rather than a drill which makes swarf.

Frank

Oo-er! But I thought the fork slider tops were delicate, hence my gentle method... 

[rtillery02]

Yes Enf. Pro, already have the new seals. Went ahead & picked up 8 of'em. I tend to do that with "serviceable" items, oil filter & tune up kits, cables & such. I just don't like havin Ollie  "down" for a long time.   R.Tillery

[rtillery02]

YES BOXERMAN, That's a GREAT help, many thanks.   R.Tillery