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Buell Forum » Knowledge Vault (tech, parts, apparel, & accessories topics) » Chassis » Suspension - Forks, Isolators, Shocks, and Swingarm » Archive through October 31, 2009 » Buell® 1997 S3 Fork Seal Replacement, Fork Seal Driver, Fork Oil Gauge, Fork Seal Bullet. « Previous Next »

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Revz
Posted on Saturday, August 22, 2009 - 02:49 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Buell® 1997 S3 Fork Seal Replacement, Fork Seal Driver, Fork Oil Gauge, Fork Seal Bullet.

After searching through the Knowledge Base I have found that there are many ways to get to the same result. (Weasel wording = I do not guarantee or endorse any of the methods ; )

Regarding the Fork Seal Driver...(Reference Factory Manual Page 2-32)

1.) You can have your Harley/ Buell® authorized dealership replace your fork seals for you.
2.) You can replace your own seals using a Buell® Tool Part No. B-41176.
3.) If you have a friend who has a metal lathe you can modify a Motion Pro® Model 08-0123 for a 41mm fork and modify like the attached drawing (see below)
4.) You can get a piece of 1 ½ “ PVC pipe, preferably a cross or tee fitting, cut it lengthwise, using hose clamps to hold the two pieces together on your forks.

Regarding the Fork Oil Gauge (Reference Factory Manual page 1-32, Figure 1-41)
1.) You can have your Harley/Buell® authorized dealership replace your fork seals for you.
2.) You can use a Motion Pro® Model l08-0121 Fork Oil Level Gauge
3.) You can use a sprayer nozzle similar to that in a Windex® bottle, cut the plastic tube to the right length (110mm on the 97 S3) and spray until no more fluid comes out.

Regarding the installation of the new Fork Seal and avoiding the lower (inner) fork tube from cutting the new seal.
1.) You can have your Harley/Buell® authorized dealership replace your fork seals for you.
2.) You can use a Motion Pro® Model 08-0274, 41mm Fork Seal Bullet
3.) You can wrap electrical tape around the top end of the lower (inner) fork tube

Links:
1.) Motion Pro® 41mm Seal driver (Same website has Fork oil Gauge and bullet)
http://www.motionpro.com/motorcycle/partno/08-0123/
2.) Badweather procedure with pictures http://www.badweatherbikers.com/cgibin/discus/show.cgi?tpc=3842&post=802080#POST802080
3.) Other pictures http://www.pbase.com/smokedaddy/buell_forks
4.) Traxxion Dynamics® Fork Seal Gauge http://traxxion.com/detail-42.aspx
5.) S3 Badweather discussion on Fork Seal replacement, http://www.badweatherbikers.com/buell/messages/4062/212226.html
6.) Another S3 Badweather discussion on Fork Seal replacment http://www.badweatherbikers.com/buell/messages/47623/294045.html
7.) Weasel wording = I do not guarantee or endorse any of the methods noted here ; )
8.) Above is for a 97 S3, check your model for variations for everything here!
9.) Last but not least.....Or you can use any of the methods that will be invariably be posted below this post.

image/bmpModified Fork Seal Driver
fork seal driver modified.bmp (52.6 k)
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Blake
Posted on Saturday, August 22, 2009 - 03:15 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Excellent. Thanks.
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Lars_77
Posted on Thursday, May 13, 2021 - 03:48 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Great instructions. I know that thread is a "few days" old...
I assume you have the WP fork in your bike?
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