I'm changing the fork tube seals on the 35mm (Kayaba) forks. Is there an easy way to get out the old seals and do I need a special tool to insert the new seals?

Thanks
Ranjet

 

You are gonna have to just pry the old seals out, after removing the circlip and washer of course.
To install the new seals I recommend you get a short length of pipe or tubing that is almost the same OD as that of the seal and use this as an install tool.
The idea is to keep the seal level as it goes down into the fork leg, then seat it firmly at the bottom of the recess. Tapping around the edge of the install tool will do this. Just light taps and let the seal slowly work it's way down..........pg

 

PG
Got it!
Thanks,

Ranjet

 

[QUOTE=piniongear;4096919][COLOR=Blue][SIZE=3][FONT=Comic Sans MS]You are gonna have to just pry the old seals out, after removing the circlip and washer of course.

PG

I had a hell of a time getting out the old seals. Chipped the top of the slider. I don't think it will cause a problem do you?

Also, what are the numbers on the bottom of the sliders?

Thanks,
Ranjet

 

[quote=ranjet;4154621]Yeah, a seal can be a real bear to remove sometimes.
The chip you show in the pic sure has straight sides to it!
This is above the seal so I do not think it is of any concern at all.
The numbers on the bottom of the sliders are most likely nothing but casting numbers put there when the legs were made. The factories keep track of the molds and dies with these numbers I believe.
Other than that, they mean nothing. You will find similar numbers cast into the parts inside your engine. They are nothing but casting numbers. Some people think they are part numbers, but a part number is going to be a 5 digit number and end in a -52, -52A, or -65, just as an example.
The 52, 65 etc is designating the year in which the last part design revision took place. The '-52' refers back to the 1952 K Model which was the first year of the Sportster fore runner. Most old Sporties carry many parts with the -52 on them...........pg

 

PG

Thanks for the reply. I chipped it with a screwdriver trying to pry them out. Looks like it was machined in there! I don't think it will cause any problems. It will be covered by the boot. Now I have to get all the front end parts together and have them chromed. I'm assuming that these are the Kayaba 35 mm forks. Can you tell? The parts catelog says there are 35, 40, and some other size. I measured them in inches and converted them to mm and I'm pretty sure they're the 35mm. When ordering parts, they refer to the original "OEM" part number. Where can you get a list of OEM part numbers?

Thanks,
Ranjet

 

The only place you can get the OEM number is from a parts manual. I have a manual for 1965 and earlier, but not newer, so that will not help you.
The most direct way is to go to a dealer and have a look at his parts manual. That will have the number listed.
Another thing to try is to log on to J&P Cycles. Look at their fork parts for your year model and they always have the OEM number beside it as I recall. The problem with this is unless they sell replacement sliders (I doubt it) there will be no slider OEM number.
Your forks are 35mm and are Kayaba. How do I know this? In 1973 they put Japanese forks on a Sporty for the first time, along with a disc brake..........pg

 

They look a like kayaba (1973-76) there is possiblility (unlikely) that they are shova (1975-83). 1971-72 models has 33.5mm tubes. You might want to rebuild whole shock assembly with seal kit...

OEM#45927-73 is for seal kayaba 35mm (1973-76)
OEM#45400-75 is for seal showa 35mm (1975-83)