I thought id post this and may help others...my oil seal leaked on the xt660r. So i had to change it..so ill speed through this so as you get the idea. the prob is getting that darn hex bolt out the bottom of the leg to separate.
ok, lets speed up...fork out, top off, spring out, oil drained....
now we are left with this ****** to get off...


so like me..u dont have tools, you dont have a rattle gun, and there is no real way to get it off. when you turn it, the inside cylinder turns....so i remember reading a post and gave me this idea...
take one of these...


standard timber rake i had..you can use a timber handle of some kind....and you take the bottom off and whittle it away like this...

so the idea is to fit it in the tube, past the oil seal to get it jammed in..you dont smash it in...you get it in so it becomes jammed.

you turn the hex..if it spins...just tap it in a bit more to get it some the cylinder doesn't spin...took me about 3 taps to get it jammed in...
once it is in tight..try to turn hex by holding handle etc...and it comes undone..as they are not really tight in there...


take bolt off with fingers...pull out broom...

place bolt back on, and there will be a bit left inside the main leg...remember how it came out...place back on so dont loose bolt etc or spring...


now pull cylinder out gently with a little bit of force..take broom out...and you end up with this....all nice and neat...


you can see the old oil seal..matter of sliding that off and placing new one..remember how it all goes on....goes in same way !

If I am just replaceing the seals...
I pump the fork with air till it pushs the seal out...
no need to pull the legs apart...

but that worked so all good....


..

__________________
Harley Davidson..
The easyest way to turn gasoline into noise with out the side efect of horse power...

yer ive seen others do that..but i was changing mine and decided to give a full clean down..the amount of gunk in the bottom leg...yuk

Did you put in 640cm3 of 10w in then fill in the air gap to 125mm with a compressed fork leg (without spring). Filled mine with 640cm3 but bigger air gap than 125mm. Do I just top up to 125mm? Ta

Yes. 640cc is just a general guide to get you roughly the right air gap. Whenever I have replaced the oil in forks on whatever bike, I've always had to add or subtract a little oil to gain the correct air gap. Just make sure the spring is still out and the fork fully compressed.

__________________

When you put the rebound tube back in, and tighten up the cap screw, look down inside the fork tube to make sure the rebound tube is centralised...

__________________
Attitude is the difference between an Ordeal and an ADVENTURE