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F650ForkMaintenance

OriginalFAQsbyKristian#562,BradG#1002,ScottID#1244
PleasereadtheDisclaimerbeforeattemptinganyworkinthisFAQ.
LastUpdated:21July2006,byWinter#1935

Introduction

ForkOilChange
Introduction
Tools
Parts
Method
Important:ForkLegCapUpstand
LoweringtheFrontForks
MixingDifferentOilsToChangeWeights
WhataboutusingATFFluidWhatisits(ATF)weight
ATFForkOil
ATFFeedback
WTF!DifferentForkOilColourinEachLeg?
WhatdoIdoifIspillforkoilonthebrake?

ForkSealChange
ChangingTheForkSealShortVersion(GS)
ChangingTheForkSealLongVersion
General
HowdoyouseeiftheForkisleaking?
HowdoIcleantheBrakes?
Tools
Parts
TighteningTorques
Procedure
RemovingtheForksandSprings
Disassemblingtheforks
ReassemblingtheForks
Time
ForkStanchionMaintenancetoPreventSealsLeaking
DoIneedtoreplacetheoringintheforkcapseachtimeIremovethecaps?
Candingsintheforkberepaired?
I'monatripandtheforksealsareleaking,help?
GSForkSealsLeaking

RemovingandInstallingForks
ProblemsRemovingForks
MyFrontAxleWillNotComeOut
Icannotgettheforkstoseparate(upper"chrome"slidertoseparatefromlower'tube')
Trickstoremovethebottomscrewoftheforkbody?

ForkProblems(Q&A)
WhydoestheF650NOThaveinvertedforks?
WhyareInvertedForksBetter?
AretheGSandDakarForksTheSame?
AretheF6509394andStrada98forksthesame?
WhatcanIdoaboutbentortwistedforks?
Howmuchdoesitcosttoreplacethefork?
HowdoIknowifmyforkshavebeenmodified?
GSCatastrophicForkFailure
ForkSealsStuck?
ForkSealsNotCoveredUnderWarranty?
ForkSealsContinuallyLeaking?
Doesforkoilgetold?

ForFAQsrelatedtoforks,shocks,maintenanceandaftermarketoptions:

AftermarketForks(includingforkprotectorsandopinions)

GSAftermarketFAQ(RacetechEmulatorsandTouratechSprings)
RearShocksMaintenance(includesglossary,suspensiontuning,andlinkagerelatedissues)

AftermarketShocks(andopinions)

OhlinsShockInstallation

SpringRateFAQ

INTRODUCTION
OneofthemostcosteffectiveupgradesforyourF650isanincreaseinforkoilweight.ThisFAQhasbeencombined
fromseveralotherFAQstohelpyoudealwitheverythingfrombustedforksealstochangingtheforkoil.

Oilvolumes(perforkleg)forOEMSprings
Bike Oilchange(Imp/USpints) Refillafterdisassembly(Imp/USpints)
ClassicF 600ml(1.056/1.268) ?
ClassicF(lowered) 650ml(1.144/1.374) ?
GS 600ml(1.056/1.268) 610ml(1.074/1.290)
GSL 610ml(1.074/1.290) 620ml(1.091/1.311)
Dakar 550ml(0.968/1.163) 560ml(0.986/1.184)
Note1:Someaftermarketspringsmayrequiremoreorlessforkoil.
Note2:Thisisperleg,soyouneedtwiceasmuchoilforacompleteoilchange!
Refilloilweight
Stockforkoilweightis7.5wt.SeealsoDifferentOilWeights
Warning:Don'tuseasharpscrewdriver!
Ratherthanusingscrewdriverstoremoveretainingclipsandsealsandsuch,I've
foundalotoftoolsupplyplacessellsurplusmedicalhandtoolsthatworkgreatfor
suchjobs.Dentalpicksandhemostatsarealotmorepreciseandhavealotless
risksofdamagingpartsthanscrewdrivers.BelievemeIknow.Andifpossible,
makesureyourgettingSURPLUSmedicaltools,notcheapnewimitations.Used
stufffromGermanyandSwedenisthebest,followedbyUSA.Thenewcheapstuff
fromIndiaandRussiaaretheworst.Theywilldothejobs,butthemetalurgyis
nowherenearasgood.(meaning,inessence,youcanlockthejawsona4mmbolt
thenusethemtoremoveasliverwithagoodpairofhemo's.Notsowithacheap
set,thejawswillbebent).dlearl#476

FORKOILCHANGE
OriginallytheForkOilChangeFAQ...
editedbyKristian#562,fortheGS.

INTRODUCTION

TheClassicandtheDakarbothhaveaconventionalThreadedForkCap.Asthethreadofthiscapisclampedbythe
UpperForkClamps,youneedtoundotheClampBoltsfirst,beforeundoingtheForkCap.TheGSontheotherhand,
hasaverysimpleCirclipArrangement,notathreadedcap.TheManualsaysyoushouldundotheUpperForkClamps,
butIhaveyettodetermineWHY,becauseyoudonotneedtoundothesetoremovetheForkCapPlugsontheGS.The
GSisverysimpletochangetheForkOilon.

YoushouldchangeyourForkOilevery20,000km.Manydoitonceayearoratleastonceevery2years.

TOOLS

AllenKeyBMWToolKit(ClassicOnly)

10mmSocketorRingSpannerforForkDrainBolt.
17mmSocketorRingSpanner(ClassicOnly)

18mmSocketorRingSpanner(DakarOnly)

TorqueWrench

ThinScrewdriverandanextrapairofhands(GSOnly).

ABarwithaRoundedendorScrewdriverwithRoundedEnd(GSOnly).

Apairofneedlenosedpliers(GSOnly).

AreceptacletocatchtheDrainedOil.

PARTS

Anappropriatevolumeofforkoilforeachleg.Seetableinintroductionforyourbike.

2#CopperCrushwashers6x10mm.BMWPart#11142343240.(IMPT:SeeNOTEbelowregardingtheParts
Number).

ORingforForkCaps.(optional).TheGSPlugalsohasanORing.Theforkoring,isaboutthesamediameterbut
somewhatthinnerthanastandardR23oring.NearasIcantell,itislikelytobeabout34x2.5mm.

NotetheDAKARhasasimilararrangementtotheClassic,withScrewedForkCaps.TheGShasaCirclip,and
isVERYSimpletoChange.

Important:WrongPartNumberForDrainPlugCrushWashers
Flash#412Notes:TheBMWpartsficheshowstheWRONGfork.Therefore,you
willgetthewrongcrushwashers.WhatyouWANTiscopperwashers6x10mm,
partnumber11142343240.(Thesearethesamecrushwashersastheoneused
forthecoolantdrainscrewwhenyouworkonyourwaterpump)Yourdealerwilltry
togiveyou31422312710whichis8x13andWRONG.ItwillnotFIT!

BTWyoumightthinkwe'remistakeninsaying"copperwashers"fortheforkdrain
bolts,andthatyoursarealuminium.HowevertheOEMcrushwashersarecopper,
theyonlylookaluminiumbecauseofthesilverspraypaintcoveringthelowerfork
tubes.Idon'tknowwhythey'dwanttousecopperinbetweensteelandaluminium,
butwhatever!
Note:ReusingCoppercrushwashers
Coppercrushwashersbecomeharderovertime,andhenceitisrecommendedyou
changethesewasherseachtimeyouperformanappropriateservice.Howeveryou
canreuseCoppercrushwashers:Inadarkishroom(i.e.notbrightlight),heatthe
crushwasheruntilitstartstoglowadullred.Youcaneitherdunkthewasherin
waterorletitcooltoroomtemperatureeithercoolingmethodisokayasthe
heatingprocessistheimportantpart.ThisprocessiscalledAnealing.

ThequestionisareyousuchaCBOAyouwillanealyourcrushwashers,orare
yougoingtogooutandbuyaboxfullfromyourlocalhardwarestorefor$10?

Caution:DonotuseyourfingerstoholdtheCopper,asyouarelikelytoburn
yourself.

METHOD

1.Putthebikeonthecenterstand.

2.Youwillhavetodealwiththeforkspringpreload,sosupportthebikeundertheframewithajack,orfromaboveat
thehandlebars.Donottryandsupportthebikeofftheplasticbashplate.Itisnotstrongenoughtoholdtheweight
ofthebike.TheGS/DakarMetalPlateisprobablyOK,IFyouputabrickundertherightplace.

3.Classics&Dakar:Dooneside(i.e.onefork)atatime,firstundoingtheupperforkclampbolt(markedyellow),
thenremovingfirstthecapontop,thenthedrainplugonthebottomoftheforkleg.UseaSIXSided17mm
SocketorRingSpanner,nota12Pointone.Whenremovingthecapkeepdownwardpressureonituntilallthe
threadsareundone,thenreleaseslowlyuntilthespringrelaxes,otherwiseyoumayruinthethreadsorthecap
mayflyoutandbonkyouonthehead.YoudoNOTneedtoremovetheMetalSpacerTubeunderneaththeCap.

HowMuchPressureontheCap?
Whenyoutaketheloadoffthefrontwheeltheirisnotalotofpressure.Iwas
abletopushthecapdownasiturned.Onceyouloosenpasttheoringyou
canpushitdownandseehowmuchpressurethereisasitmovesthethread
gap.You'llbefine(noneedforanothersetofhands).Justpressdownwith
onehandwhileundoingwiththeother.

Asafirsttimerbeware:Youhaveextremelyfinethreads,asteeltube,andan
aluminumcap.Moresoontherefit,butbeextremelycarefulwiththeamount
ofpressureyouputdownwardsonthecap.It'sreallyeasytobungthose
threadsupinthealuminumcap.

Asforremoval,Iuseasocketonashortratchet,gentlypushingdownonthe
capasIturnit,adjustingthepressuretofeeltheleastresistance.It'smost
importantasyouneartheendthestrengthofthespringiseasytoresistwith
yourhandpressure,butit'salsostrongenoughtopushpastonethreadonthe
capandbungupthatallimportantfirstthread.

Thankstoseveralcontributors

IfyouuseaSocket,Isuggestyougetonewhichhasn'tgotaBevelattheleadingedge,orgrindanormal
bevelledsocketdownonemmorsosuchthattheHexisflushwiththebottomoftheSocket.(Alternativelytrack
downthenearestSnapontruckandgetasixpointflankdrivesocket.Thesehaveareliefinthecornersofthe
hexsothattheyrestontheFLATSofthebolthead,notonthecorners.Theywillabsolutelyremoveanyhexhead
fastener,nomatterhowroundedthecornersare.Willprobablycost$20,butcheaperthanruiningtheplug.You
maybeabletoorderfromwww.snapon.com,butwouldhavetopayS&H.Chuck#1124)

IMPORTANT(ClassicOnly):IfthetreeclampholdsthecapandyoutryandundothecapBEFOREyouunder
theclampboltsityouwillRoundtheCapBolt.,likeoneofthepreviousownersofmybike.UndotheClamp,
markedyellowinthePhoto,FIRST.Kristian#562.

4.GSOnly:Dooneside(i.e.onefork)atatime,firstpriseofftheblackPlasticCapwithafingernail(No
Screwdriverneeded!).TesttheplugwithaThumbfirsttochecktheexpectedresistance.Thenusingyourrounded
rodorscrewdriverhandle,PUSHtheexposedplugdownasfarasitwillgoandholditdown.Usingyourextrapair
ofhands,insertathinscrewdriverbehindthespringwirecirclip(atthediscontinuityintheclip)anduseapairof
needlenosedpliersorascrewdrivertoliftthecirclipout.GENTLYallowtheplugtocomeupoutoftheforkuntil
thespringrelaxes,thenpullitoutslowly.YoudoNOTneedtoremovetheMetalSpacerTubeunderneaththeplug.
Thenremovethedrainplugonthebottomoftheforkleg.

5.MakesurenooilspillsontheBrakeDiscorCaliper.Cleanitoffyourwheelandrim.Aftertheoildrains,replace
thedrainplugbolt,torquingtojust6Nmandusinganewcrushwasher.IMPORTANT:(Seenotebelowregarding
theCrushWasher).

6.Slowlypourthemeasuredamountofoil(seetableforoilvolumes)tothefork.

7.Classics&Dakar:Replacethecap(usinganewORingSealifnecessary).IMPORTANT:Screwitonvery
VERYcarefullybyhandfirst,makingsureitstartscorrectly.IfitjuststartstoJam,undoitandtryagain.The
pitchofthethreadisveryfine(1mm)andcaneasilyberuinedbycrossthreadingit.

8.Classics&Dakar:TorquetheCapto25NmandthentorqueuptheForkClampBolt,alsoto25Nm.

9.GSOnly:Replacetheplug(usinganewORingSealifnecessary).Pushitinandagain,usingyourroundedrod
orscrewdriverhandle,PUSHtheexposedplugdownasfarasitwillgoandholditdown.Usingyourotherhand,
insertthespringwirecirclipuntilitclipsintoplaceinthegroove.Tryandaligntheclipsothediscontinuityisatthe
front,thisstops(alittle)watersittinginthediscontinuity).SLOWLYreleasetheplugandwhenyouaresurethe
Circlipwillholdit,removetheroundedrodorscrewdriverhandle.ReplacetheBlackPlasticCap.

10.RepeatwiththeotherForkLeg.

11.MakesureyoutightenallForkClampBoltsClassic/EnsureCirclipisProperlySeatedandtheForkCapsare
secureBEFOREtakingoutthesupport.

IMPORTANT:FORKLEGCAPUPSTAND
RAG#014Notes:ThefirsttimeIchangedtheforkoil,Ifoundthecapsflushwiththetripletree.Thetreeclamp
mayholdthecapalsoasthedealersnowsetthecap3mmabovethetree.Ofcoursethisisofnoconcernfor
motorbikeswithloweringkits.Todothis(ONELEGatatime)youmustALSOunderthe2lowerclampboltsas
wellastheUpperOneandmovetheentireforkupuntilyougeta3mmUpstandfromthetopsurfaceofthetriple
tree.

LOWERINGTHEFRONTFORKS

Flash#412Notes:Ifyouwanttoloweryourbikesome,takeagoodhardlookatwheretheforktubesgothrough
theupperandlowersteeringhead.Youprobablyshouldputajackunderthebikewithabitofwoodorcardboard
protectingthebottomofthebike.ThepartsdrawingisForkDrainPartsDwg.NotethatthereareTHREEscrews
numbered3oneachside.Loosenallsixofthesescrewsseveralturns.Letoffthejacksome.Ifthebikedoesn't
dropdown,raisingthetubesinthesteeringhead,youmayneedtoGENTLYapplythetipofascrewdrivertothe
splitsinthecastingsofthetripletree.Loweringyourbikewillquickenyoursteeringsomewhatandchangethe
handling,sodonotattemptthisunlessyouknowwhatyouaredoing.

MIXINGDIFFERENTOILSTOCHANGEWEIGHTS

7.5Wistoolightunlessyouweightabout80pounds.Itmakesforareally"cushy"rideratherthanonethat
handlesbetter.Ifyoupreferthefreewaytotwisties,use7.5W.Ifyouprefertwisties,useatleast10W.Flash412

BMWsays7.5wtForkoil,butmanyfolksprefer10wt.(Ilike10wt.)Youcanmixequalpartsof5wtand10wtto
get7.5wt.

Doubtmanywouldnoticethedifferencebetween8or9wtoilinthebudgetF650forks.Especiallyastheviscosity
thinsduetoshearingovertimeanyway.Thebiggestissue(IMHO)withmixandmatchisthecompatibilityofthe
fluidsandadditives.MixingaoilbasedonPolyalkyleneglycol(PAG,synthetic)witheitherapolyalphaolefin(PAO,
synthetic)orstandarddinooilisveryincompatible(PAO,estersanddinoarecompatible).Butyou'lllikelynotfind
thiscompositioninfoonthelabel(perhapsonamaterialsafetydatasheet(MSDS)).Ifyoumustgothisroute,
suggestmixingabitoutsideofthebikeinaclearcontainersoastoobserveforincompatibilityBEFOREputtingit
inthebike.Theoiladditivescouldalsobeincompatiblewitheachother.Viscositiesarenotlinearfunctions(closer
to,butnotquitelogarithmic).Forviscositiesascloseas7.5and10,thedifferenceisprobablynotworthbreaking
outthescientificcalculator.Marty#436Chicago97F650F.

WHATABOUTUSINGATFFLUID?WHATISITS(ATF)WEIGHT?

byRand#1111

Thefollowingisamessagepostedtothe"TransAlp"listwhichIalsoread.Iamnotanengineerandleaveittoothersto
consider.ItseemsthatAnton(fromtheTAList)hasspentalittletimecheckingouthisinformationanditmightbegood
toincludeintheForkFAQ.

ATFForkOil

Hmmm...Averyinterestingquestion.Isearchedthewebandfoundthefollowing:

Viscosityrequirementsforautomatictransmissionfluidsvarywiththeapplication.Transmissionfluidsvarywiththe
application.Transmissionfluidsinautomotiveapplicationsareusuallymultiviscosity,rangingfromSAE0W20to10W
30,andincludeviscosityindeximproverstoallowadequatelowtemperatureperformance.Powershifttransmission
fluids,ontheotherhand,areoftensinglegradefluids.

Example:

EssoATFDEXRONIII/MERCONisavailableinonegrade.ComparedtoSAE5W20engineoilsandSAE75W80W
gearoils,ithasaboutthesamehightemperatureviscositywithapproximatelya5Cfluidityadvantageinthelow
temperatureoperatingrange.

Someadditionalexplanationaboutthedifferencebetweenthemotoroilandthegearoilviscositygradingsystems:

Viscosityisthemostimportantpropertyofagearlubricant.Aswithmotoroil,theSocietyofAutomotiveEngineers
(SAE)developedaviscositygradingsystemforgearlubricants.TheSAEsystemlistsrequirementsforbothsingleand
multigradelubricants,butdoesnotdifferentiatebetweenEPandnonEPfluids.TypicalSAEgearlubricantgrades
includeSAE80,90,140,75W,80W,75W90and85W140.Althoughthegradenumbersarelargerthanthoseassociated
withmotoroils,gearlubricantsarenotnecessarilyheavier.Thetwoseparategradingsystemsareusedtominimize
confusionbetweenmotoroilandgearlubes.

ATFFeedback

ItwouldbeinterestingtoknowhowtheforksealsholduptoATF.UsedtobeyouwouldrunATFincar
powersteeringunits.Mostcompany'shavespecialfluidnowforpowersteeringbecausetheATFeatthesealsand
causedlotsofleakage.TheF650G/Salreadyhasaforksealleakageproblem.AnyonerunningATFintheforks
foralongperiodoftimewithoutforksealleakage???Steve1130Or

ATFweightappearstobearound0W20equivalenttoautomotiveoilscale,althoughyouprobablyhavenoconcern
forthe"W"value,asitisdeterminedat2040F.Whencomparedtotypical"forkoil"viscosities,itappearstobe
around10(atleastMobil1ATF).Butkeepinmindthattypicalautomotiveoilshaveaviscosityindexinthelow
100s,ATFsarecloserto200,whilegoodforkoilscanrangefrom150to400.Nottomentionthe
presence/absenceofazincantiwearadditive,antifoam,rustandoxidationinhibitorsorotherdifferences?Andthe
typeofshearthatgoesoninatransmissionisalotdifferentthaninafork.Seriously,doyouthinkmostoil
companiesWANTtocarry18differentvarietiesofhydraulicfluid,whenone(orjustusingATF)wouldsuffice?Not
tosaythatitwouldn'twork(forawhile),butthenagain,canolaoilfromyourgrocer'sshelfmightwork,too.
YMMV!!!Marty#436Chicago97F650F

IamsuretechnologyhasprogressedsomewhatbutATFiswhatisspecifiedintheHondashopmanualforuseas
forkoilinmyCX500.WhenIchangetheforkoilonthatbikeinthespringIwillseewhatitlookslike(thebike
wasstoredallseasoninafriendsbasementasIdidn'thaveenoughtimetorideboththeCSandtheF).Iknow
thatthebikehandledwellandforksealsdidnotleakforthefullyearthatIrodewiththeATFintheforkunits.Fork
oilonit'sownisnotexpensivebutbikefluidsbrake,coolant,oil,chainlubestartstoaddupandwhenyouhave
acoupleofbikesandliketochangethefluidsregularlyitisnicetoknowiftherearesubstitutionsthatcanbe
safelymade.Sameascrossreferencedairfilters,oilfilters,bulbsetc...Rand#1111

WTF!DIFFERENTFORKOILCOLOURINEACHLEG?

TypicalQuery:I'vechangedyesterday(forthefirsttimesinceI'vegotthebikefromthepreviousowner)thetelescopic
forkoil.Rightforkhadbrownishoil,whiletheleftforkhadsomegreyishoil.Thetwofluidsdidn'tmixinthepanandthey
appeartobedifferent.Theirquantitywasaround600mlx2,sobasicallycorrect.Anythoughts?Itseemssounlikelythat
theyusedtwodifferentfluids,oneforeachfork?

Answer:Variousmanufacturersusedifferentcolorstodenotedifferentweights.ThelasttimeIchangedmyforkoilinmy
F650,IusedredHonda10weightinoneforkandgreenSpectro10weightintheotherfork.Iwasjustcleaningoutmy
stockofforkoil.Aslongasbothoilsarethesameweightandyoudonotmixthem,Iamnotconcernedaboutwho
makestheoil.Allbrandnameforkoilsarejustfine.IalwayslikedKalGardforkoil,butitisveryblack,havingMoS2
suspendedintheoilandlooksdirtywhenfirstinstalled,somostdealersdon'tcarryit.Nowthatyouhavereplacedtheoil
withnew,don'tworry,behappy.Richard#230

Ihavechangedtheoilinhundredsofforksanditisnotuncommonfortheoiltolookcompletelydifferentfromthe
2legs.Steve#417(in,us)

ThankstoElHombreSinNombre,Rag#14,Flash#412,Todd#389.

WHATDOIDOIFISPILLFORKOILONTHEBRAKE?

I'mdoingmy12Kserviceandchangingmyforkoil.OfcourseIwouldspillforkoilonthebottompartofmybrakedisc.
SoI'mgonnagogetacanofbrakecleanerandsprayitgood.Isthatallthereistoit?Citizen

That'swhatbrakecleanerisFOR.Gototheautopartsplaceandgetacan.Youdon'tneedtoremoveanyparts.
Justhosedownthepadsandthediskfrombothsidesasyouspinthewheel.Applythebrakesfromtimetotime
andhoseagain.Flash#412

Ifyoudon'tdoagoodjobofcleaningyourbrakediscswithcontactcleanerlikeEmperorFlashhaswisely
recommended,youcouldglazeyourdiscsomewhat.Ifthathappens,youWILLnoticeadecreaseinstopping
power.Takethewheeloffandusesome600gritwetanddrysandpapertocleanthedisc.Iwouldstrongly
recommendagainstrubbingperpindiculartothedirectionofrotation.IOW,youshouldonlyrubinthedirectionof
rotation.Shouldtaketheglazeoffprettywell.
WorkedwellformeandI'vebeenputtingmybrakestothetestsinceIsquirtedforkoilallovermydisklikearipe
dumba**.IahdcontactcleanerbutfailedtoseethatIgotsomeontopofthepadsandsoglazedmydiskabit.
BOLand,asalways,proceedwithcaution.NC

FORKSEALCHANGE

CHANGINGTHEFORKSEALSHORTVERSION(GS)

byAdamx#1001,29/11/01

Thequickprocedureis:

TheforksealkitisBMWpart#31422312836.ThisistheKitforONESealandONEDustCover.YouneedTWO
sealsandTWOdustcovers.

1.Putbikeoncentrestand&jackbikeupsofrontwheelisjustoffground.

2.RemovethebrakecalliperandABSsensorifyouhaveit.

3.Undotheclampboltandaxle,slideitout(don'tdropthespacerinthedirt),rolloutthewheel.

4.Undoforkclamps&brace.

5.Slideoutleg.

6.Priseoffdustsealandremovethespringclip.

7.Priseouttheseal.Gentleapplicationofbruteforce.There'snoBMWtooltotake'emout,thereisonetoput'em
in.Basically,ripitoutwithoutscratchingthestanchion.

8.Ifyoudon'tusetheBMWkit,NGK8844180BR20031isitsnumber.Cleanleg,insertsealuseBMWtoolto
fit.313620CE91isthetool#.Oryoucouldtryusingabitofwood.

9.Reverseouttathere.

Note1:(24/02/02):AstheprocedureisalmostexactlythesamefortheGSasfortheClassic,particularlyoncetheyoff
thebike.

Note2:ThenewerGSforksealshavewhatlooklikeaspringaroundtheoutsideoftheseal.Theyaresupposedtolast
longer.Brad,#1002

CHANGINGTHEFORKSEALLONGVERSION

OriginalClassicFAQby:Spakur,David#476&
Mal#1011,PhotosbyMal#1011.
AdditionalcommentsbyPat#1214
editedbyKristian#562

Writtenfrommemoryandwithsomehelpfromrepairhandbooks.

SeetheFrontWheelRemovalFAQandtheSteeringHeadBearingReplacementFAQforforadditionalinformation.
ForQ&AonLeakingForkSeals,DingedForkTubesetc,seetheForkSealFAQGSDakar

GENERAL

ItisImportanttochangeBOTHoftheForkSealsassoonasyounoticethatoneisleaking,theotherwillprobablysoon
break.Why?BecausetheforkoilwillprobablydripontotheBrakeDiscmakingtheBrakesdeteriorate(Ithappenedto
meafter45.000KM).

HowdoyouseeiftheForkisleaking?Pushtheforksdownacoupleoftimes(usetheFrontBrake)andlookifthereis
anyoilontheUpperSliderthereshouldn'tbeany.IftheOilhasbeendrippingontotheBrakeDiscyou'llalsohaveto
cleantheBrakeDiscandtheBrakeLinings.
HowdoIcleantheBrakes?Dothiswithsomesolution(forremovingoil)andifthatdoesn'thelpuseametalfileor
someSandpaperonthebrakeLinings(nottheBrakeDisc!)toremovetheouterlayer(rememberthattheliningsare
madeof"soft"materialthatwill"suckin"theoil.IntheworstcasebuynewBrakeLinings.ThisiswhatIdid.Referthe
BrakePadFAQ.

TOOLS

Thetoolsyourequireasfollows(note:whilesomeotherbikesrequireaspecialtooltoholdthedamperrodwhileyou
undotheboltsinthebottomofeachforkleg,theF650doesnotneedanyothertoolsotherthanwhatismentionedin
thisFAQ.

AllenKeys(inyourtoolkitorbetterstilloffa1/2"or1/4"drivetoattachyourTorquewrenchto).

An10mmSocketorRingSpanner.

An17mmSocketorRingSpanner.

TorqueWrench.

CirclipPliers(notabsolutelyrequired).

AVice.

APropaneTorchorBlowTorchforheatingtheForkiftheoldSealishardtoremove.

AspecialForkToolforinsertingthenewForkSeal.Imanagedwithoutone,butittookawhilelonger(nexttimeI'll
getone).

Drifts,Hammers(metal/rubber).

PARTS

Anappropriatevolumeofforkoilforeachleg.SeetableinIntroductionforyourbike.

BMWPartNumber(s) Item
CopperCrushWashers6x10mmforForkOilDrain.(IMPT:SeethewarninginthePartsfora
2x11142343240. ForkOilChangeforfurtherinfo).YouMAYbeabletoreusetheoldones,atapinch,butthey're
cheap.
ORingforForkCaps.Theseyoucanbuygeneric.TakethemtoaGeneralBearing&Sealring
2x31422345383 shopandaskforareplacementOilSealingORing.YouMAYbeabletoreusetheoldones,at
apinch,butthey'recheap.
2x31422312838 ForkSeals
2x31427681274 NewstyleGSforkdustsealtheonewiththespringaroundit
2x31422312710 CrushWashers.YouMAYbeabletoreusetheoldones,atapinch,butthey'recheap.
Note:HondaPartNumbers
Theroads?ofLabrador,NFLD,etcdidinoneofmyforksealssoIcheckedout
theFAQ'sandprintedthegoodandproperadviceandorderedreplacementseals
plusanewsupplyofforkoil.Oneweeklater,thedaybeforeIshoulddepartforthe
Jailbreak,stillnoseals.AndIreallywantedtoridetheF650,althoughIhave
severalotheroptions.BelievingFLASH,asalldo,IknowthatBMWdoesnotmine
theorefromwhichitmakescrankshafts,doesnotmakeitsownsealsand
bearings,etc.So,Iwenttothemultifareasternbikedealershipandaskedfora
sealsetformyShowafork.IgetH*ndapartnumber51490MN8305anditisthe
exactduplicateofthesealanddustcoverthatIhaveremoved.Allafewmilesfrom
myhouseinsteadof270milesliketo"my"dealer.'Hopethismayhelpsomeone.
Regards,Ike647'97F650

BMWFORKSEALKITFORAGS:#31422312836
H*ndaEQUIVALENT:#51490MN8305(USD$22forbothsealanddustcap)
NothingClever#1441

Theexactsealdimentionsare:54x41x11mm.Writingincludes...NOK...
884...4180...BR20031...29...Flash412(C)
TheforksealswefoundhereweremadebyK&SinSanDiego.Theydon't
listtheF650Gsontehpackage,buttheyarethecorrectsize.Twofingers
#1717

TIGHTENINGTORQUES

ClassicTorqueValues
32Nmor50Nm
2#AllenBoltsFrontBrakeCallipertoForkleg
(checkyourmanual)
4#ClampNutsWheeltoFrontAxleClamp 12Nm
1#FrontAxle 80Nm
2#UpperForkClampScrewsonForkBridge
25Nm
(HoldingTripleTreetoForks),MarkedYellow.
4#LowerForkClampScrews 25Nm
2#ForkOilScrews(beneathFork) 6Nm
GS/DakarTorqueValues
Clampsonforkstanchion 21Nm
Slidingtubetobridge 25Nm
Axle 40Nm
Axlelockbolt 20Nm
Callipers 40Nm

PROCEDURE

RemovingtheForksandSprings

1.Theprocedureisquitesimpleandrequiresfewtools.TheBMWmanualsuggestsremovingtheentirefrontofthe
biketodothis,butIknewmySteeringHeadBearingsweregood,soIthoughtthatRemovingtheGasTank,
FairingandTripleTreewasjustneedlesswork.Ifyouhaveanydoubtsaboutyours,youmayaswelltakeitall
apartandreplacethebearings.AccesstotheForkClampsisalittleeasierwhentheTank(withsidefairings)is
removed,soyoumightjustwanttoremovethat.Ifyouchoosetoremovethefrontfairing,don'tforgettoloosen
the2cablestotheturnlightsandthecabletotheheadlight.Justsqueezeyourhandinbehindthefrontfairing
whendoingthis.

2.Firstthingistoliftthebike.Iboughtamotorcyclejackthatworkeddandy.AvailableatCostcofor$100,it's
somethingI'vewantedforquitesometime,andthiswastheperfectrationalizationtobuyit.Ittookacoupleof
triestogetjusttherightlift,untilIfoundatwobyfourundertheskidplateandthetwocenterstandmountslifted
thebikeperfectlystraight.Iusedtiedownstotherearrackandjackanditwasextremelystable,allowingmeto
movethebikearoundtodealwiththelimitedspaceIhadtoworkonit,whichwouldhavebeenaproblemwiththe
frontendremoved.Thatsaid,I'msureyoucoulddothejoonthecenterstandifyouwanted.Donottryand
supportthebikeofftheplasticbashplate.Itisnotstrongenoughtoholdtheweightofthebike.Takeitoffifyou
haveto.

3.Thenremovetheplasticfromthefrontwheelthefenderandthecalipercover.Thenthecaliperitself.Imadea
hookfromaclotheshangerbentintheshapeofa"C"andhungthecaliperfromtheplasticradiatorsurround.This
keepsitoutofyour,aswellasharms,way.Nextwasthefronttire.Loosenthefourboltsontheaxlekeeper(no
needtoremovethem)andunscrewtheaxlewiththe12mmAllenwrenchThenIremovedtheforkbrace/fender
support.

4.Atthispointyouhavethebikesuspendedintheairwitheverythingremovedfromtheforks,whicharenowready
toberemovedthemselves.Asstatedpreviously,themanualsaysthefairingandgastank(aswellasthe
handlebarsonanST)shouldberemoved,butIfoundthisunnecessary.Bysimplymovingtheforksleftandright,I
wasabletogetmyratchetintoundothebolts.

5.FirstIloosenedthetopboltoneachtripleclamp,(markedyellow)thenIundidtheforkcap,takingcaretokeep
thespringpreloadfromshootingthecapacrosstheroom.Youdon'tneedtoworrytomuchaboutthisasthereis
hardlyanypreloadonthestockforks.Awordofcautionhere.Theforkcaps(17mm)arealuminumwith
extremelyfinethreads.Theforksaresteel,withaspringpushinguponthecap.Inordertokeepfromdamaging
thethreads,especiallythelasttwoorthree,it'simportanttokeepdownwardpressureonthecapasit's
unscrewed.Ifoundaclosedendwrenchworkedbestforthis,keepingdownwardpressureonthecapwithmy
fingerwhileIresetthewrench.Remember,youshouldbeabletoloosenandtightenthiscapbyhandoncethe
torqueisbroken.Ifitwon't,there'sagoodchanceit'scrossthreaded,sobecareful.Doingitbyhandalsogives
yougoodfeedbackontheamountofdownwardpressureyouusing.

6.Oncethecapsareout,youcanremovethespacer,washer,andspringfromthefork.Thenit'stimetodrainthe
forks.Getacontainerreadyandopenthe10mmboltonthebackofeachfork.Thefirstlittlebitcomesoutata
goodratesobecareful.(Ifoundasupplyofoilabsorbentcloseathandwasinvaluableforthisentirejob,BTW).
Letitdripforawhile,itwillsaveyoucleaningupamesslateronasquiteabitisstillintherewhenitstops
flowing.Atthispoint,puttheaxlebackintokeeptheforksfromturningandundotheboltsinthebottomofeach
forkleg,whichholdthedampingrodsinplace.Whenundoingonlyhalfaturnwilldoaslongasit'sbrokenloose.
Leavethemisplace,justfingertightfornow.Nowtaketheaxlebackoutandremovetheforksbyundoingthe
twoAllenheadboltsonthelowertripleclampandcarefullyslidingtheforksoutthebottom.

7.Youcannowtakeeachforkintotheworkshop.

Disassemblingtheforks

1.Takingthemapartallowsyoutocleanthem,inspectthebushingsandreplacetheseals.Thisisaccomplishedby
removingtheboltsfromthebottomoftheforksandturningthemupsidedown.(UndocompletelytheScrew
HoldingtheSlideratthebaseoftheLowerForkleg.Hereitisremoved)Thedampingrodandtopspringshould
fallout.Thencarefullyplacethelowerpartofthefork(outertube)inavice,andusingtheupperpart(innertube)
asaslidehammer,pullthesealout.Intheverybottomoftheforkisacupwhichgoesbetweenthedampingrod
andtheoutertubewhichisveryimportant.Ifyouelectnottocompletelydisassembleyourforks,itisnecessary
togetthiscupincorrectlyonreassembly.AtthispointIwouldlayoutallthepartsandcomparethemwithan
explodedpictureoftheforksfromthemanualorpartsbook,sothatyouknowyouhaveeverythingandyouknow
whereeverythinggoes.Thismentalpicturewillhelpyoulateron,whenputtingitallbacktogether.

2.DismantletheOuterForksbystartingwiththe"DustSeal",usingsomethingthintoliftitup,andbecarefulnotto
damageit.Underneathisacirclip/snapringthatyou'llhavetoremovewithyourcirclippliers.(Note:
veggie_deluxefoundtherewasnoneedforcirclippliersyoucanuseasmallflatscrewdriverinstead).
Mal'sApproach
Youhavetopulloffthesliderbytheslidehammermethodi.e.Becausethe
stanchionbearing/bushisalargeroutsidediameterthantheboreoftheslider
bearingbushtheywon'tjust"pull"apart.Theideaistowarmthealloyslider
soastoreleasethebushwhenthetwobushesbangtogether.Thestanchion
bushstaysinplaceandthesliderbushcomesoutalongwiththeringand
seal.Minedidn'tworklikethat.Thebushstayedpartwayintheslider.This
pictureshowsthefix.WiththestanchionbushremovedIusedthegrooveit
sitsinasanextractorforthesliderbush.Letthesliderhangatananglesothe
groovehooksupbehindthestuckbush.Acoupleoflightblowswiththerubber
hammeranditwasout.Ihadn'twarmeditenoughbeforehand.
Spakur'sApproach
NowisthetimetoremovetheForkSeal,thisisdonewiththesocalledslide
hammertechnique.WhenIdidit,itwasreallystuck,somountitinavice(use
somesoftmateriallikerubberorathickragbetweentheforkandtheviceso
youdon'tdamagethefork)andstartusingtheslidehammermethod,which
meanspushtheForkallthewayinandthenpullitoutasfast/hardasyoucan
(tryfirsttobegentlebutifthatdoesn'tworkdon'tbeafraidtouseallyour
strength).Ifitstillisstuckuseablowtorchorsomethingelsetoheatthe
outsideofftheFork.Whenyou'vegottheSealouttherestshouldfollow.
Againrememberinwhichorderthepartswerein.Seealsothispictureofthe
order.HereistheLowerForkwithSealRemoved.

3.ChecktheforkSliderisstraight!Here'sabentoneoffadamagedbike.

4.CleantheForksandcheckthesliderforscratchesdamages(placeswereoilcouldleakout).

5.Takesometimeforareligiouscleaningofalltheparts.Forthechromeforktubescarbcleanerandawellworn
ScotchBritepadworkwell.InterioroftheoutertubeIusedcarbcleanerandaHeavyDutypapertowel,buta
cottonclothwouldworkwelltoo.

ReassemblingtheForks
1.Nowit'stimetoreassemble.Placethedamperrodcupintothe(immaculatelyclean)outertube,thespringover
the(equallyimmaculatelyclean)dampertubeanddropthepairdownthe(immacul...yougettheidea)innertube.

2.ThentheinnertubegoesintotheoutertubeandwiththedamperrodfixingboltontheendofanAllenwrench(T
Handlesworkthebest)fiddleaboutuntilyougetthethreadsstartedandtightenitdown.Don'tworryaboutthe
torqueatthispointbutrememberit'sonly25Nmsodon'tmakeittootight!ApparentlytheClassicManualsays
20Nm,ifsomeonecanconfirmplease?

3.Nextopenyourbrandnewforkoilbottle(Youmightconsiderchangingto10wtfrom7.5wtatthisstage)andputa
littleonthetopbushingaswellassplashalittlebitdowntheoutertube.(Ohyeah,don'tforgettoreplacethedrain
plugfirst,DOH!).

4.Squeezethebushinglightlyandgetitstarteddowntheoutertube.Nowit'stimeforaSpecialTool.Youcanget
oneatanyM/Cshopfor$40$50ordowhatIdid,get11/2"PVCpipecouplerandgrindthecenterstopoutofthe
ID.Thisfitsoverthe41mminnertubeperfectly.Thensimplytapgentlywithahammeruntilthebushisin.For
thelastlittlebitputthewasherintothetubeaswell.Whenthewasherhasbottomedoutyouknowthebushingis
inasfarasitwillgo.(Note:Tempo#1908states"ThesuggestiontouseaPVCcouplertosetthebushingis
brilliant.Butit'sa1.25"coupler,not1.5".A1.5"couplerdoesnotfitintheslider.FortunatelyIcaughtthiswhileI
wasatthehardwarestore.Istillboughtoneofeachjusttoverify.")Ednote:Cansomeonepleaseconfirmthe
appropriatesize?.

5.NextlubeuptheINSIDEofthesealwithgoodole#10.Ifyougetanyontheoutsidewipeitoffandslideitdown
overtheinnertube.Makesurethewritingonthesealisupandyoucanseethespring.(anotherDOH!)Then
placetheForkSealTool*ontopofthesealandtapdowngentlyagainuntilthesealbottomsagainstthewasher.

6.Fitthesealretainingcirclip/snapringintoit'sgrooveusingthecirclippliers.

7.Nextlubeupthedustcoverandpressitdownfirmlyoverthetopoftheseal/sealretainingclip.
Mal'sapproachtomakeaDrift
(ForkSealTool)todrivetheSealin
Idecidedtomakeadrifttodrivethesealinwithoutdamage.Myold
andtrustedmethodis:Takearegularholecuttinggadgetandaplastic
kitchencuttingupboard.
PickthetwobladesthatarethenearesttotheID/ODoftheseal.The
importantpartisUSEBOTHBLADESATTHESAMETIME.
Goinfromonesideoftheboardtoabouthalfwaythenfinishofffrom
theother.Sanddownforagoodfit.
Theplasticwheel(centre)ispokedout.
Thethingdidn'tquitecomeoutintwosoIfinishedthecutwithacraft
knife.
Showsthecutbits.AsyoucanseeI'vecutafewdifferentsizebitsoff
theboardforotherseals.
Driftonit'sown.Driftinsitu.Driftinsitu2.
Acheapandsimplemethodoffittingseals.Ikeepallthewheelsfrom
thecentreastheycanbeusedonotheropenseals.
SpakurNotes(ReassemblingtheOuterFork)
InsertthepiecesyouremovedaftertheSealandthenputtheSealin.
HereistheinsertionorderontheStanchion.
Don'tforgettheDampingGuideontheendoftheDamperRod.
WheninsertingtheSealtheProfessionalsusesomekindofspecialtool
forthis,thetoolfitsaroundtheforkslider,becausetheydon'twantto
damagetheForksliderortheForkSeal.
Imanagedwithoutone,usingdifferenthammers/drifts,butbecareful
nottoscratchtheSliderordamagethenewSeal.
Ihadtousealotofforcetogetitallthewayinsothatthecirclipcould
befitinitsplace/hole.TheSealshouldbefittedevenly!
Mark#403'sApproach
Itooka12"longpieceof1.5inchwhite(sched40)pvcpipe,cutit
downthelengthofit,carefully(soasnottoburnit)heateditwitha
propanetorchtogetitsofter,andstretchitopenalongthecuttofitthe
41mmforktubes.Coldwater"lockedin"thenewdiameter.
Thisisnowmyforksealdriver.workedperfectlyandcostabout$1.not
sureif2inchpipewouldhaveworkedwithoutmodification.Ididn'thave
anyonhand.
Youcanalsobuyaforksealdriver.onceyougettheforksoffandtake
themapart,it'sprettyeasytoseehowtoreplacetheseals.However,if
youhavealeakingseal,youMAYALSOhaveadamagedforktube
causingtheleak.

8.YoumightconsiderchangingtheOilonthebike,butensureitstillontheJack/Prop.Don'tforgettochange(and
oil)theTopCapOring(ifyouboughtone).

9.Torqueuptheboltsinthebottomofeachforkleg.Withregardstothesebolts:Alwaysloosenfirstandtighten
last.That'sbecausethedamperassembly/tubeitscrewsintoneedsthepressureofthemain/longspring
pressingonittopreventitturning.Whenundoingonlyhalfaturnwilldoaslongasit'sbrokenloose.Thesame
applieswhentighteningit.Nipituptothecorrecttorquewhenthetopcapisscreweddown.Thatmeansof
coursethetopcaphasthengottoberemovedagainfortheoiltogoin.Thiscanbedonebeforethelegisfittedto
thebike.

10.ChangetheOil.SeetheForkOilSectionfordetailsofOilVolumes.Oncetheoillevelisset,it'sreadytobutton
up.i.e.ReplacetheTopCap.

11.ReassembletheForksonthebike.Don'tmixupleftandright!theforksshouldstickup3mmabovetheFork
Bridge.Anotehere.Unlessyouhavealoweredbike,whenyoudisassembledyourforksthetopofthecapwas
evenwithtopofthetoptripleclamp.Thisspechasbeenchanged.ThetopoftheINNERTUBEshouldprotrude
3mmabovethetopofthetripleclamp.3mmUpstand.AtthispointIjusttightenedthetwoAllenboltsonthelower
tripleclamp,justenoughtokeeptheforkinplaceandtorquetheforkcapandthedampingrodkeeperbolt.NextI
puttheforkbraceon,thenthewheel.Torquedtheaxlebolt,leavingthepinchboltsjustfingertight.Thenthetop
forkpinchbolts,gettingthebikeoffitsstandorjackand,Isatonitandcompressedtheforksseveraltimes.This
linesuptheforksandaxle.ThenItorquedthelowerforkboltsandtheaxlepinchbolts,thenundidandretorqued
thetopforkbolts.

12.ReassembletheMudguardandtheWheel.

13.ItisalsoagoodideatocheckyourSteeringHeadBearingPlayafterreinstallingtheforks,ifyouhavetheTankoff
anyway.

14.Nowallthatisleftistoreplacethecaliper,calipercoverandthefender.Andride.

15.Don'tforgettosqueezethebrakehandleafewtimesafterreinstallingthewheeltoensureyourbrakes"takeup"!

TIME

Spakur:"IthinkIspentabout1012hoursworkingonit,butthiswasmyfirstmechanicalMotorcyclejobdonealot
sincethensowiththerighttoolsandsomeexperienceI'dsayabout6hourstofinishit.".GoodLuck!

Feedback

Thesliderbushonthe'nonleakingside'wasacompletebitchtotakeoff.Whentheslidehammermethodwas
usedthestanchionjammedatthetop.Whentheyeventuallypartedcompanybothbusheswerewornforhalftheir
depthsotheyrodeuponeachotherandcausedthesticking.Thedampercuptookabitofabuseinthisprocess.
Theleakingsidecameoffintwohits.Therewasagrey/blackcoatingonthebushestheir'rubbingsides'.Itlooked
foralltheworldlikeTeflon.Icleanedthembutnottoorigorouslyincaseitwassomefrictionlesscoatinggiventhe
application.Pat#1214

FORKSTANCHIONMAINTENANCETOPREVENTSEALSLEAKING

ThankstoMarty#436

Q.DoIneedtoreplacetheoringintheforkcapseachtimeIremovethecaps?
A:Someprefertobecautiousandreplaceiteachtime.Thepartisnotexpensive.However,ifyoudon'thappen
tohavenewonesonhandoryouaredoingsometuningandrepeatedlyremovingthemtheycanbereused.Just
takecarewhenhandlingthecaps,especiallyduringrefitting.TheBMWpartnumberoftheseis31422345383.If
youneedtobuythematahardwarestoretakeyourwithyoutocompare.Theyareabout2mmX37mmO.D.

Lotsofpeopleaskabouthowtoremovethecapsinthefirstplace.Thisdependsonwhichmodelyouhave.The
Classicscommonlyhaveacapthatistreadedandscrewsinandout.ThenewGSmodelshavetwodesigns.The
Dakar'shaveathreadedcapbutthestandardGS(notsureabouttheCSyet)hasacapretainedbyaninternal
circlip.Thecirclipisaccessedbypryinguptheblackplasticcapwhereyouwillseeawirecliparoundtheinside
ofthetube.Useapickorsmallbladescrewdrivertoworkitout.BEWAREthecapisbeingpushedupbythe
springs.Youwillhavetopressdownonthecaptoremovetheclipanditwillpopoutwhenyourelievethe
pressure.Puttingthebikeonastandisagoodideaanddoingonesideatatimemakesiteasier.

Q:I'vefoundadingintheforkandthesealonthatsideisleaking.Canthisberepaired?Ihavedinged
forkStanchions.HowcanImakethemlastaslongaspossiblebeforeIhavetoreplacetheseals?
A:Maybe.Dependsonhowdeepthedamagegoes.Somemembershavehadsuccesssmoothingoutthe
damageenoughtosolvetheproblem.Anewsealisneededofcourseasitisalreadydamaged.Theobjectiveis
smoothingthedingistoremoveanysharpedgeandmakethedefectlargeenoughthatthesealwipercandrop
intothesmoothedareatoachieveaseal.Thescaleofthisrepairisverysmallthough.Removingtoomuchofthe
forktubesurfacewillexposethebaseandweakenthetube.Alargedingmaynotberepairableinwhichcaseyou
willneedanewforktube(therearecompaniesthatreconditionforktubestoo).Thesmoothingcanbedonewith
veryfineemeryclothoraknifepolishingstone.Useasmall,flat,knifesharpeningstonetogrinddownthe
positivewithouthurtinganymoreofthesurroundingareathannecessary.Thenegative(crater)willprobablyleaka
bitoffluid(likelynegligible).BesureyougetoffALLtheroughedges(runaladiespairofnylonsoverit,they'll
snagontheslightestedge).AndPLEASEgooutandbuytheforkgaiterswe'vebeenrecommendingforAGES
(theyshouldhavebeenstandardequipment).

Youcancheckyourworkusingapairofnylonstockings(ladiestypeofcourse).Iftheysnagyouneedtokeep
polishing.Therepairworkshouldbedonearoundthetubenotverticallytogivethesealthebestchancetowork.
Youmaystillhaveasmallweepbutifthisisnotcoveredunderwarrantyitcouldbuyyousometime.Then
preventmoredingsbyaddingforkboots(akagaiters).

Seethemodificationssectionbelowforideas.Ifyoujustsuspectaflawintheforktubebutcan'tfinditherearea
coupleoftricks:

Coatthetubewithathinfilmofgrease.Compresstheforksfully.Ifthereisanickyoushouldseeanareawhere
thegreasewasnotwipedclean.
Usethenylonstockingapproachmentionedabovetofeelforthenick.

Q.I'monatripandtheforksealsareleaking,help?
A:Thequestionishowbad.Mostsealfailuresonlyallowsmallamountsofoilbyandontoyourforks.Asmall
amountofoilgoesalongwayandcanlookworsethanitis.Acompletelyblownsealwillbeaproblemthough.
Thethingstolookoutforareoddhandlingcausedbythechangeindampening,bindingifalotoftheoilisgone,
theoilgettingontothetireandorthebrakediscrotorandpads.Asmallweepisnothingtopanicoverandthe
leakingoilcanbekeptincheckbyusingaragtowidedowntheresiduewheneveryoustop.Onememberusesa
socktiedaroundtheforktoabsorbtheoil.Beextracarefulwithaleakingleftsealasithasabetterchanceof
lettingoilrunontothebrake(yourbrakeswillfailtoworkwithoilonthem!).

GSFORKSEALSLEAKING

byAdamx#1001,November'01

WhenBMWreplacedafirstsealforme,thetechnicalexplainedthattherehadbeenafaultybatchworldwide,butthe
designhadbeenchangedtoadoublelippedtype.Theoriginaldesignwasusedinseveraldifferentmodelssonotit
wasn'tjustaF650GSproblem.Nowitappearstheremaybeasecondduffbatchormaybeamanufacturingfaultinthe
GSlegs?

ToPREVENTithappening,seetheAftermarketForkFAQ

Pleasesendusyourstories,info,BMWreactions.It'sobviouslyaproblemworldwide.Postingsbelow:

I'mnowlookingatTWOnewforksealsformycanary(yellowGS=tweetybird)....havinghadonereplaced2
weeksago,nowbothappeartobegoingu/s.isthisthenews&s?anyothershavingthisproblem...(Alex#871I
sawyou!)Adamx1001

Yep,apparentlyI'vegotthesameproblem.MyGSisabout10monthsold,hasabout2500milesonitmostlyover
hillytwistyroads.Noticedoilresidueontherightforkonthelastride.Leftforkisclean.Iamheadedbacktothe
dealerforwarrantyrepairalongwithfailedcomputer,newsoftware/injectorupgrade,andrecalledrearbrake.
SeemslikealotofproblemsforanewBMW.Stan#770

Samething.Forksealblewandthelocalshopreplacedbothofthemjusttomakesure.David

Metoo,2001Dakarsealonrightforkreplacedinthefirstmonth,itisleakingagainnow8monthsand21000km
later.Mydealerhasorderedanewforktubeasitispittedandistearingtheseal.Shouldbeanotherfewweeks
beforeitishere.Asacomparison,mywife's97F650with46000kmhasnotneededsealsreplaced.Adrian#668

I'monmythirdone,underwarrantyrighthandside.Dealerclaimsit's'causePhoenixisreallyhot...Art#884
Myfrontforkleakedafter7000km,butIridealotongravelroads.Afterthis,IinstalledrubberbootsfromBMW
100GS1988modelpart#31421458220.Theyfitwell,evenitthetotallengthdoesn'tcoverallofthechrome
tube.Unfortunately,thecrossbracemustbemodifiedtoallowyoutoinstallhoseclamp.Theclampswill
guarantee,thatbootstayon,regardlessofridingterrain.Jerzy.

MyDakarwasbuiltin4/01,andbought1yearago.Itstallswhendownshiftingoccasionally,andsurgesbadly
between3500&4200RPM's.Nowwith1700milestherightfrontforksealleaksverybadly(startedat700miles).
IamtakingitintomylocalBMWshopsoon,theysaythere'snoguaranteethattheBMWwarrantywillcoverthe
oneforksealw/1700milesonit(awearableitem)buttheywilltry?AMCNut.

ForkSealsfor2001F650GSIhavethesamebike.2,800milesleftsealblew.Howeverourlocaldealeriscrap.
Theclosestone200miles(Denver)Iboughtasealanddustcoverfromthem,hadthelocaldirtbikeshopreplace
itfor$60.00Cheaperthandrivingforme.GoodLuckPatrick.ColoradoGuy.

HiEveryone!Iwouldappreciatefeedbackonthefollowingsituation.IhaveanF650GSwith8300miles.Oilis
startingtoseepoutoftheforksealsontothebarsveryfaintly,veryslightlybarelynoticeable.Itookthebiketo
thetotheBMWdealershiptodayandtheytoldmethatthisisacommonproblemwiththe650theforksealsand
thattheyhavetobereplacedapproximately8000mi.orsooner.HasanyoneexperiencedthiswithyourF650's.If
thisistrue,isthereanywayaroundit?ThanksandRIDESAFE.Jim.

Ihavean'01GSandminewentoutatlessthan3,000milesreplacedunderwarranty.Itrytokeeptheforks
cleanuntilIgetaroundtoinstallingforkgators.Inmycase,Idomostofmyridingwheretherearelotsofbugs
andIthinkitishardenedbuggutsstucktomyforksthatdestroyedtheseals.Ihavenottakenmy'01GSoff
road,Iwashitregularlyincludingcleaningbugsandsuchofftheforks,andmysealswentoutatabout2,500
miles.Iboughtforkprotectorsbuthaven'tinstalledthemyet.Iamwaitingforthenextsealfailure,thenwillhave
thedealerinstalltheprotectorsatthesametimetheyreplacetheseals.WhenIcleanbugsofftheforks,
sometimestheyarereallystuckandhaveformedquitehardlittlelumps.Idon'tseehowanyrubbersealscould
standuptothat.ForkprotectorsshouldhavecomeasstandardequipmentmaybetheywillsomedayifBMW
hastokeeppayingforsomanysealreplacements.Stan#770.

I'monmythirdpairofforksealswithonly8000mionmy2001GSA.Anybodyelseseemtogothroughthese
things.Idosomedirtriding,butnotwheelieslikethedealerisaccusingmeof.Also,wherecanIfindSebring
exhaustintheUS.ItriedtofitaRemusonmybikebutitwouldn'tfitwiththefactorysidebags.Thanks.Michael
(Haven'tpostedinawhile)#883.

Lotsofpeoplehavehadsealsreplacedandthatincludesme.NoproblemsinceIputthebootson.BradG#1002

Mydealernowacceptsthattherewasafaultybatchofseals.Thesealsheusedasreplacementsdidnothave
theringyoudescribeandstartedleakingstraightaway.Doyouknowwhetherthesealswiththeringhavea
differentpartnumbertothesealswithoutthering?Theboots(whichIdon'thave)aretoprotecttheforks.AsI
understanditthesefaultysealsleakregardlessofwhethertheforksarepittedornot?I'mabitworriedthatifIfit
forkbootsIwillnotbeabletoseewhetherthesealsareleakingornot.AndrewC(UK)

"AsIunderstanditthesefaultysealsleakregardlessofwhethertheforksarepittedornot?I'mabitworriedthatif
IfitforkbootsIwillnotbeabletoseewhetherthesealsareleakingornot"Yes,that'scorrect.Minewere
replaced(twice)aswell.I'mnotsureifIhavetheoneswiththeringbutI'mhesitanttoputonbootsforthesame
reasons.Ifyougetbootsthatarewideenough(i.e.,nottheMSR),youcouldjustloosenthematthetopandslide
themdowntoseeifthere'saleak.(Oryoucouldjustcheckifyoursteeringfeelsloose...)its_xls2001F650GSA
SanJose,CA.

OryoucoulduseTriumphplasticforkstoneguards,whichsellforabout$15anddonotrequireremovingthefork
toinstall.Richard#230

REMOVINGANDINSTALLINGFORKS

PROBLEMSREMOVINGFORKS

jessehasgonethroughtheprocessofmanylittleproblemsdisassemblingtheforks...thefollowingquestionsarebased
onseveralthreadscoveringmanyproblems.Note:Fordetailsontheproceduretoremoveandinstalltheforks,seethe
ForkSealChangeProcedure.

MyFrontAxleWillNotComeOut

Loosentheaxleclampsfirst.Theaxlemayalsobebent.
Icannotgettheforkstoseparate(upper"chrome"slidertoseparatefromlower'tube')

Didyouundothedamperrodboltinthebottomofeachforkleg?Thatboltandthecirclipareallthatholdthe
bottompartoftheslidertothetoppart.Robin#790

Yep(andthanksfortheinstantreply!)I've'loosened'thatboltoneachfork:
ononeforkitisstilldifficulttoturn,andwon'tcomeout
ontheotherforkitiseasytoturn,andwon'tcomeout
Thatboltshouldcomerightout,right?jesse

Thatboltshouldcomerightout.Ican'tatthemomentthinkofwhatkeepsthedamperroditself(whichthebolt
connectsto)fromrotatingalongwiththebolt.Areyousurethattheupperforklegisn'trotatingasyouare
attemptingtoloosenthebolt?It'spossiblethattheonethat'sdifficulttoturnisjustspinningthedamperrodinside
thefork.Heck,that'spossibleontheonethat'seasytoturn,too.Robin#790

Ifyouhavetheboltsout...Ishovedthetubeinthesliderasfarasitwouldgoandthenquicklyandforcibly
yankedonthetubewithonehandwhileholdingthesliderintheothertogetthemout.Thistookseveralattempts.
AtthetimeIthoughtthiscan'tberight,I'mgoingtobreaksomethingbutIguessittakesthatkindofforce.Didn't
needaviseandheatwon'thelpunlessyourcold.Maybesinceyoursarebentsomuchyoucan'tgetagood
runningstartyankingonthem?patobravo#1754

Alrightfinallygottheboltsoutandtheforksapart.Thesliderandwerenotspinning,butthedamperrodwas
spinninginside.IhadtoputtheforkWAYintocompressioninordertogetenoughfrictionintheretoletthebolt
comeout.Thanks!jesse

Trickstoremovethebottomscrewoftheforkbody?

What'sthetricktogetthebottomscrewoutoftheforkbody?Igotittobreakloose,butnowitjustspinsandwon't
comeallthewayout.grofmon#1857

Justshovesomethingdownintheretokeepitfromspinningwhileyouundothebolt.Tempo#1908

Yeah,Ifigureditout.Iusedabroomhandle...grofmon#1857

Anothertrickistouseanairdrivenimpactwrenchtopullthatboltout.Theinertiaoftheforkinternalswillhold
theminplaceenoughtogettheboltout.Justdon'tusetheimpactwrenchtotightenitup!Bryan,#179

FORKPROBLEMS(Q&A)
WhydoestheF650NOThaveinvertedforks?

Ifallgoeswell,IshouldbetestridingaF650DakarthisThursday,andplacingordersubsequently.Beingadirtbiker,I
keeplookingatthatspindlylittlesetofforksandwonderingwhyonearthyouwouldn'tputasetofinvertedforksona
400poundbike.Especiallyafterlookingatthebrochurewithpicturesofaguyactuallyjumpingthebeast.Ihavenoplans
ofairingitout,butI'dfeelbetterdropping$9kifithadsay48mminverts.HomeMadeSin

Why,indeed...ThepowersthatbeatBMWarenotaboutwhat'srightorgoodforthecustomer,they'reaboutwhat
makesmoney.Ifyoucansellallthe$9000dollarmotorcyclesyoucurrentlymake,withlowrentdamperrodforks,
whywouldtheyupgrade?Harl#380

WhyareInvertedForksBetter?

Flash#412,07Oct01

Whenthebiggertubeisthelongertube,theforkisstiffer.Stiffermeansthatitflexesless.Ifitflexesless,you
haveabettersenseofcontrolandinfactDOhavebettercontrol.

Thereisalsosomethingcalledthesprungtounsprungweightratio(sometimesjustcalledunsprungweightratio).
Thisreferstotheweightofthevehiclemechanicallylocatedbelowthesuspensiontotheweightofthevehicle
mechanicallylocatedontopofthesuspension.

Consideringtheengineeringextremewillhelpyouunderstandwhythisisimportant:
Ifyourbikeandyouweighed1000poundsandyourwheels,forklowersandswingarmsweighednothing,
whenyouhiteitheradiporabumpintheroad,theattitudeofthebikewouldnotchange.Theridewouldbe
supersmooth.Conversely,ifyourwheelsandstuffweighed1000poundsandyouandyourbikeweighed
200pounds,everydiporbumpintheroadwouldthrowyouupordownwiththewheels,nomatterhow
greatthesuspension.
Invertedforksputtheheavierbitsinthesprungcategory,whichimprovessuspensionactioncomparedto
theidenticalpartsinstalledconventionally.Thelighterthebike,themorenoticeablethiseffect.

Andthatiswhyinvertedforksarebetter.

AretheGSandDakarForksTheSame?

TheDakarandGSusethesameforklowersthetubes/slidersarethereforethesamediameter,butontheDakar
theyarelonger,andtheyuseathreadedcapversustheclipontheGS.djw#1736

Aftermeasuringmy(damaged)sliderstheyappeartobethesamelengthastheGSsliderpatobravohas.Doyou
happentoknowwhatthelengthsare?Dealerconfirmedit'sadifferentPNanddifferent(~$30)cost.Other
differences,likethethreadedvs.clipcap,areimportanttoo.jesse

Justtoclarifywhatwe'retalkingabout...Whatyou'vepicturedthefichecallsa"stanchion"(orwe'vecalledita
tube).The"slider"(whatIcalledtheforklowers)isthepartthatholdstheaxle.TheslidersareidenticalfortheGS
andtheDakar.Thetubes/stanchionsaredifferentfortheGSandDakar.SoI'mconfusedifpatobravohasaGS
stanchionthatisthesamelengthasyoursitmusthavecomefromaDakar.

P.S.Afterfurtherconsideration,sinceIhaveneverhadGSandDakarforktubessidebyside,theymightbethe
samelength.Differentpipes,spacersandspringsmightenablethetubestoextendfurtherfromtheslidersonthe
Dakar,givingtheadditionaltravelandtheappearance(fromtheoutside)thattheDakartubesarelonger.djw
#1736

Itisthesamelength/diameterasthestanchionsIhadonmyDakar.Theonlydifference,Icantell,isthe'cap'.
Thedakarhasathreadedcap,theGSforkhasa'popin'cap(Ithink).jesse

AretheF6509394andStrada98forksthesame?

Yes.SeethePartsFiches(thankstoFlash#412andFede

WhatcanIdoaboutbentortwistedforks?

Asasummary,adriverinthesmalltownofAbancay,Perucrashedintoourbikesparkedonthesideofthestreet(two
F650GS/Dakar2002).Thehandlebarandthetopoftheforkareperfectlyaligned.Thetopoftheforkandthewheel,
however,arenolongerata90degreesangle.Theforkistwistedbywhatseemstobea2or3degreesangle.pierresas

Loosenthetopandbottompinchboltsslightlyaswellastheaxle.Standinfrontofthebikewithyourlegson
eithersideofthewheelandYANKitbackstraight,thentighteneverthingbackup.ItMIGHTbethenothingis
actuallydamaged,justmisalignedintheclamps.SometimesitlooksliketheFORKSarebentanditisreallyjust
handlebarsmisaligned.Youmighttrylooseningthebarsandyankingthembackstraight,too.Flash#412

OftenbentpartscanbestraightenedbytheFrameManinSacramento,CA.Flash#412

Idunnoaboutthefoolinfectedbikes.ButasetofCBR600F2forkswillsliprightintotheclampsofaFunduro.
Flash#412

Howmuchdoesitcosttoreplacethefork?

Withnewparts?Probably$1600ormoreforeachbike.Withused...maybe$200apiece.Ihadtwoforktubesand
thetopandbottomclampstraightenedfor$150,shippingincludedbytheFrameMan.Flash#412

HowdoIknowifmyforkshavebeenmodified?

I'vecheckedtheFAQsafewtimesandamwonderingifmyforksweremodifiedbythepreviousowner.Hereisthe
situation:Thefrontwheelhopsonrelativelysmoothroadsurfaces.Itdoesthisconstantly,atanyspeed.Thetiresare
balanced.Overlargebumpstheforkcompressesandabsorbstheshock.Smallbumps,nada.todd911

Iwouldtrythe10wt.oilintheforksfirstoff.Ifit'sstilltojumpy,gotothestock7.5wt.Sofareverythingis
relativelycheap.Youwouldhavetodiassembletheforktofindoutifanymodshavebeendonetoit.Haveyou
triedcontactingthepreviousowner?Mybike'sexhasbeenveryhelpfulinthatregard.Jetdoc,#1546
FWIW,ThefirstthingIdowhenIgetanewbike,orgetoneofmineoutofstorage,ischangeALLthefluids.That
way,Ihaveaknownstartingpoint.Oil,Coolant,Transfluid(ifit'sseparate)Forkoil,brakefluid.Idon'tcareifthe
sellerswearshejustchangedit,Ichangeitagain.ThenIKNOWwhat'sinthereandhowlongit'sbeenthere.I
thinksomediggingwouldyieldthelengthofthestockspringsandspacer.Ifyoucan'tfinditanywhere,Icould
checkmystockstuffatstorageifyou'dlike.Ifyouopenyourforksupandthere'sapieceofPVCpipeinthere,
they'vebeenmodified.David,#476

GSCatastrophicForkFailure?

IownaF650GSthatIreceivednewinJuneof2000.Afterabout5,000miles,Iexperiencedacatastrophicfailureofthe
castingsonbothsideofthefrontforks.Isustainedmajorinjuries.BMWhasadmittedtoknowingof3nearlyidentical
failuresbeforetheyredesignedtheforks,addingmorematerial.Theydecidednottonotifyowners.I'mwonderingifany
ChainGangmembersknowofsimilarfailures.Gertarg'00F650GS

Iforgottomentionthatasbothsidesoftheforkssnapped,thefrontwheeldepartedthebikeleavingthebikeand
medoing3flipsastheforksdugintothedirt.Bythewaythefrontwheelisinalmostperfectcondition.Ididn'thit
anything.Gertarg

ThatisthefirstinstanceofthathappeningthatIhaveeverheard.Trevor#999

Backin'02Ipurchasedsomepartsfromaguyoftheinternet...IthinkitwasofofIBMWR,can'tremember...they
werenewspareshehadforalongtourdownsouth.Hewasinjuredreallybadforafewmonthswhenhisfrontend
cameapart,butIcan'trememberifhesaidtheforksorthewheelitself.Italkedtohimthroughemailandonthe
phoneandI'mtryingtofindtherecordsofwhatIpurchasedandthentonarrowitdown.Hedidsaythathewas
involvedwithsomesortoflegalactionwithBMWatthetimeduetohissituationnotbeingthefirst,althoughhis
storywastheonlyoneI'dheardofuntilnow.Iwonderifhe'sthesameguy?beem_dubya#1328

ForkSealsStuck?

Inthemiddleofreplacingtheforkseals,pertheFAQ.NowatthepointwhereIguessIamgoingtohavetouseHEAT.I
thinkIreadMaltosay"warmtheslider."andSpakursays"heattheoutsideoftheFork."Whichisit,andwhereexactly
ontheforkorslidershouldtheheatbeapplied?davidbwatkins#651

DBW,Ididthisjobafewweeksagoanddidnothavetouseheat.Myadviceistotrybruteforcefirst.Iclamped
theforkinaheavybenchviceandgrabbedtheotherend(movable)andjerkeditlikeIwastryingtotearitup.
'Hadtodothismorethan23timesbeforeitreleasedandcameout.Ifyouuseheatyouwillstillhavetojerkit
out,Ibelieve.Heattheheavyportionofthefork,ontheoutside,aroundwherethesealislocated,ontheinside.
Watchoutfortheresidualoilandremainingparts.Havefun!Ike647

ForkSealsNotCoveredUnderWarranty?

Theotherday,InotedthatmyBeemerwasleakingfromtheleftfork.Iloggedonhere,foundoutitwascommon,but
sinceitisan'02,figuredIwouldcallthedealerinDenver.Iwastoldthatforksealsarenotcoveredundertheirwarranty.
Iaskedwhy.Hesaid,basically,thatithappenedsofrequentlythattheychosetoexcludethemfromtheircoverage.I
thoughtIwashearingthings!tannlege

DaveyououghttodowhatwedohereintheUK.Don'ttakeyourdealer'sanswerasthefinalanswer.Askyour
dealerforacontactemailaddressorphonenumberforyourBMWCustomerServicesdept.Whenyoucontact
them,remembertheyarehumansjustlikemeandyou,andsodon'tgetirate.Justputyourpointofviewand
requestthattheygiveaninstructiontothedealertodothewarrantywork.Gettheirname,letthemknowhow
greatyourbikeisandmakefriendswiththemforfuturereference.

It'softenassimpleasthat.I'vespokentoallmycontactsintheUKBMWCustomerServicesdeptandInow
occasionallyactasanintermediarytosetllewarrantyclaimsand/orexcessiveservicecharges.Theremustbe
someoneontheUSAsectionoftheChainGangwhohascontactswithyourBMWServicesfolkbynow.Isit
BMWNAyouguysdealwith?LetyourDealerknow(ina*nice*way)thatyouintendtotakethemattertoahigher
authority.Trevor,#999

Dave,IagreewithTrevoronthisone.Don'ttakethatdealer'sanswerasthegospel.Ipersonallyknowofoneguy
whogothisdamagedforksealsreplacedunderwarranty.Iwouldtryanotherdealer.Aftergettingthemrepaired
underwarranty,Iwouldconsiderusingforkboots.Especiallyifyoudomuchoffroad.Seacuke#1214

Thankstoeveryoneforyourinput.IanandcrewupinNorthernColorado(Loveland)tookcareofme(althoughI
amsurprisedthattheydidn'tchangebothseals...theleftonewasleakingbuthowfarbehindcantherightone
be?)Toansweryourquestions,itwasFoothillsthatgavemetherunaround,andeventhoughitis50moremiles
eachwayformetogotoLoveland,Iwillgothere(althoughIamgoingtocontacttheowneratFoothills).tannlege
ForkSealsContinuallyLeaking?

Ihavebeenfightingalongrunningproblemwith1forksealonmyGS.Ihavebeengettingabout5000kmbeforeitstarts
toleak,changethesealandtheprocessstartsalloveragain.So,Idecidedtoreplacethestanchion(sp?)BMWshreaded
mywallettothetuneofA$303anditcamewiththeslidingbushfitted(thoughtthatwouldhavebeenanextra!)

Idecidedtoalsoreplacethesealintheothersideatthesametime.IntheprocessIalsodecidedtotryanewforkoil
whichalsoshreadedmywallet!LikeA$39for2litres.ItsSilkoleneVI300ProRSF10weight,lookspurpleincolour.isa
fortifiedsyntheticoil.Thisoilappearstohavebetterdampingthantheordinary10weightIwasprevusing.Ialsoreused
myextrawasherspacerstoaddmorepressuretotheforkspringsthanstandard,makingthebikesitupalittlemoreat
thefrontandgivemealittleextratravelwithoutbottoming,inbadterrain.An11pmtestrideshowedanicefirm,well
dampedfrontendwithnoleaks.......sofar!jack

IhadasimilarproblemwithoneofNancy'sbikes.Keptchangingthedamnsealanditwouldstarttoleakinabout
1000miles.IthoughtI'dexaminedtheforktubewell,butfinallyfoundalittletinyblemish,likelyalittlerock
impact.CarefullypolisheditoutwithanArkansasstoneandVoila...Noleaks.Interestingcommentsontheoil.I'll
becurioushowwellitlasts.Andatleastyouhaveasparetubenow.Harl#380

Doesforkoilgetold?

Iknowthatoldbrakefluidinanopenedcontainerabsorbsmoistureandisbestdiscarded.Butwhataboutforkoil?Ihave
ahalfbottleofforkoil.Itwasopened,thenclosedabout1.5yearsago.Useitortossit?Raymo,#1173

Notifitisinaclosed(notfactorysealed)container.Itis"work"thatmakesforkoil"old."Ifitwasleftinanopen
container,itmayhavedustandbugsandothercrapinit.Bottlewithacapon,Iwouldn'tworryabout.I'duseit.I
have,manytimes.Flash412(CO)

ImustadmitIkindawishtheline"Loosentheaxleclamp"
hadbeeninlarge,boldfontintheFAQ.
ItwouldamadeaxleremovalMUCHeasier.
Ijustthoughtitwassodifficultbecausemaybeitwasbent...jesse

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