1987 FZR250 fork seals

[KIPS powervalve]

Hi all,

Just bought a damaged FZR250 2KR (1987). The cooling system is bung, but so are the fork seals, and have ruined the front brake pads as a result.

Never done fork seals, but I have watched somebody do it, and watched YouTubes on the subject. What all those forks have in common is a nut/threaded cap on top of the stanchion. The FZR does not. It looks like it has a steel plug cap rammed in and possibly welded. Anybody know how to take spring and damper out (oil has been drained)?

Help would be appreciated.

Ta

[R650R]

First off check why they are leaking, is there any stone chips or marks on the stanchions cutting the seals, if so they will only cut the new ones too.
I did my own, pretty straightforward. Didn't know about measuring stuff like that back then so ended up butting too much oil in, took it round the side of the house, opened the bleed screws and pumped the forks once and she was good from there on.
Sold it to my brothers mate and he got the pegs down all the time so must have done something right with my guesswork!

[Yow Ling]

The bung in the top of the forks is not welded in, it is most likley held in with a circlip that may be hard to see or is hidden.
You need to get an appropriate tool, or a bit of broomstick and press the bung in to uncover the circlip, pop it out wwith a screw driver and gently reduce the pressure on the broomstickthe bung will slide out, be carefull, there is a spring behind there just waiting to hurt you.

[KIPS powervalve]

Thanks, I'll give that a shot.

[KIPS powervalve]

Thanks Buddy, it worked! Although the spring nearly penetrated the roof of the garage. :Oops: I'll put a rag over the other one