Dino’s Tinker Shed, S2Ep34 How to replace the fork seals on the Suzuki DR650
Fork seal replacement can be an intimidating project for many home mechanics, myself included, but it does not have to be. With a bit of planning, research, and a few specialized tools you too can accomplish this project with little to no drama.
This is a long video for sure, but I wanted you to see all the steps and what to expect if you choose to tackle this project. As I say in the video you will require a few specialized tools whether you buy them or make them yourself, but the investment will be less than if you have a shop do the work and guess what? You have the tools forever and knowing that seals wear out you can use them again on your bike or a friend’s if needed.
As always and because this video is so long, I have included time code chapters for you to skip around if needed.
Hope you enjoy it, Dino
Time code chapters:
00:00 Cold opening
00:52 Introduction
01:11 Overview of the project
04:29 Pre work cleaning
06:39 Importance of a manual
07:44 How to remove the front wheel
11:40 Removing the fork tubes from the bike
14:56 Disassembly of the fork tubes
20:56 Specialized tools
28:03 Inspection of old seals
28:52 removing old seals and bushings
30:59 DR650’s lower fork option
33:31 Fork oil selection
35:21 Fork reassembly
39:20 New seal installation
43:12Filling with oil
46:52 Installing forks back in the bike
47:30 Installing front wheel
49:56 Summary


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