[Benny477]

I found out once you get the bottom off the seal is like a small fork seal. I`ll try and take some pics,but I never have posted pics before. What`s best way to post pics?

[crfsonly]

here's a how-to post a picture link:

http://www.crfsonly.com/forum/viewtopic.php?t=13007

ken

[Benny477]

Ok,here`s the end of the cartridge rod and peened marks that neede drilled. You need a special tool also I found out from suspension direct that fits into the allen end on bottom.

I`ll update when I get seals and special tool to finish.

[Benny477]

Well not the greatest post with pics,bear with me.

[crf450319]

Well, I haven't been on this board in a long time but I was searching on Google for some info on how to replace the cartridge seals and this thread popped up. So I thought I'd share what I learned. The fork pictured is from a 2007 crf450r :

Wow, from what I'd read online I was thinking I should just send the cartridge(s) away to have the seals replaced. Which would have been a complete waste of time and money.

I should mention that I do all of my own suspension work, I service my forks (both chambers) and replace the shock fluid every 20 hours of runtime. So far, the only job I'd farm out is a re-valve as there's just too much trial and error to do that on my own. So maybe if you've never had a set of forks apart, this job might not be for you ?

3 things I learned :

#1) This is far too easy to do, knowing what I know now I'd never even consider sending the cartridges away to have the seals replaced.

#2) There's no need what so ever to spend $59.99 + shipping on a shaft holder, not that it wouldn't be a nice tool to have, but completely un-necessary.

#3) ** MORE THAN LIKELY THE MOST IMPORTANT ** The thickness of the outer cartridge wall is approx. 1.51 - 1.6 millemeters thick, I more than likely didn't drill more than 1.4mm into the dimples. I'd drill for 2 or 3 seconds, then look at how far I'd gone, then drill 2 or 3 seconds and look. I did that until I thought I'd gone deep enough - Keep in mind you only need to go about 1.5mm.

Here are some pics :



At this point I'd already had the seal head out, before I'd had it out the drill mark looked uniform and I couldn't really see the threads. I used my 2lb propane torch to apply some heat before I put the allen wrench on, I spent about 2 minutes warming the cartridge.

Bought this 17mm allen head wrench for $22

[crfsonly]

excellent post. so reinstalling it are you using loc-tite? blue/red?

ken

[crf450319]

Hi Ken,

Thanks ! If we all share info. everyone involved will benefit.

I think I'd go with blue loc-tite, there wasn't any loc-tite on the threads that I could see so I'd guess there wasn't any applied at the factory ? I'm not real crazy about the red stuff (just my personal paranoia), I'm guessing the blue would suffice. Keep in mind that my guess is just that, a guess.

Although I do have some red in my tool box....

[crfsonly]

the peening keeps the cap place so with those drilled out i believe loc-tite is required. the red stuff does take heat to loosen up to removed but it's not going anywhere otherwise.

ken

[Benny477]

Great post,I`m still waiting on parts to finish mine but have a much better idea of what to do.

[Benny477]

Okay I got parts and got the seal head off. I`m replacing the seal and bushing,I figure with everything apart replace what you can right. Do you need to heat the head piece a little to punch out the bushing? I thought when I put it back together I`ll freeze the bushing and heat the head piece again with a little wd 40 should slide right in.

[Benny477]

Ran into anther problem,when I put the rebound rod into the cartridge and screw on the end cap the adjuster won`t work. I`ve made sure the inner rod drops in all the way and the flat parts line up but then it won`t turn left or right.

[crf450319]

So your rebound clicker won't turn ? I'm a little unsure of what exactly you're talking about, but I'm guessing that your rebound adjuster isn't working.

When you take your rebound clicker off the dampning rod can you turn the clicker in either direction ?

[Benny477]

I got it fixed.

[crf450319]

How ? What was the problem ?

[crfsonly]

yes...inquiring minds want to know.