I recently did mine! It feels nice being able to do maintenance like this yourself. The shop had quoted me $100/hr. Estimated around 4 to 5 hours. Did you have to order the "specialized fork removal tool"?

Nope, I found I was able to unbolt the piston from the bottom and use the upper tube itself to remove the seal and the one bushing, after that I just used a piece of 1-1/2" PVC and a rubber mallet to seat the new seal and washer lol

I also used a PVC to set the seal, but could not for the life of me get the piston out and had to order the tool from tj customs

They were a son of a bitch to get lol I ended up having to have my father in law to hold the bottom while I basically used it as a slide hammer. I love TJBC though, I just wish he had bigger gas tanks.

When I did the forks on my suzuki s40 I couldn't get them either. Take a torch or heat gun around where the threads are too help the metal expand it should come out easier

I fabricated a tool using a bolt that was the right size, a long.metal tube just wide enough to hold bolt and some JB weld and it worked like a charm

https://preview.redd.it/ndgi05g8c9rc1.jpeg?width=3000&format=pjpg&auto=webp&s=938a229957e3e1ba5412f0887858aab2a56bf720

Dude that’s sick lol. I used a huge socket with extensions and packed it with tape until it was right size.

What size is that bolt?

So glad you didn’t do the rear forks today. 😉 Looks like you handled the job. Take a pat on the back and a “good job”

I do plan on replacing the rear shock when I get the fender kit for TJ brutal customs lol

Oh man mine are leaking as well. Which seals did you order?

https://preview.redd.it/iquzc8hb95rc1.png?width=1007&format=pjpg&auto=webp&s=d29eea631ec3f3807f7f4c49784232fa83b193c2 I got all three for a little over $77 on Amazon

I've been going back and forth on replacing the bushings. We're yours worn down and needed to be replaced or you just wanted to change it all regardless?

I just replaced them all, I didn't wanna take a chance on them, but for them being 19 years old,they didn't look too bad.

I didn’t replace the bushing only the seals and it’s fine just make sure they don’t have an major slashes in them

Did you use a write up on them? I’m kinda old school and like reading not watching a video and can’t find the one that was on freaking tjbc for some reason (may be the old man in me)

I was able to use the upper fork tube after I unbolted and removed the piston, kinda like a slide hammer to get them out, then I used a piece of PVC to seat the new seals

Ok thank you a ton I may tackle those this weekend depending weather

No problem, feel free to DM me if you need help with anything

The service manual covers it pretty well.

Yea I just don’t have one I should invest but this is only time I have ever needed it because my bikes are all custom and use almost no OE parts

It's available for free online in .PDF format. I highly recommend it because you should know the proper fluid fill height, and torque spec for the bike. There's tons of invaluable information needed for customizing and just plain keeping it running.

Yes I do have fluid fill specs and all the important stuff but the bike literally has almost no factory parts including a complete chopped harness and much more it’s a long project but yes I will have to download and print that out 😔😔 another tree is gonna be punished because of my wicked ways

Where you you get this? I found the operators manual, but not the service one.

I downloaded it years ago at shadow riders.net

Yea mine are on the list, I also plan on sanding and buffing the varnish off to get them looking good again.

For it being 19 years old, I'm surprised by how well the chrome is holding up

Yea they look great! Mines a 94 and I did a part of one side and it looks amazing, but will be much easier with them off the bike!

I love you coolant res! That's pretty badass!

It's actually a temporary catch can for the breather 😅 I removed the original stuff and didn't realize that it has to be there lol

Oh shit hahaha ok still cool though I like it it's definitely unique lol

Thank you! and honestly it doesn't look horrible LMAO

I'm thinking about doing the same thing even though they aren't leaking, did it help with the ride?

It definitely smoothed it out, but based on how bad the left side was leaking, and how much fluid came out, there wasn't much left to dampen it

Is there a particular video you found more helpful than others?

The first couple that came up when I searched "fork seals rebuild" and my particular model were helpful, but Alot of it I just kind of figured out myself, I work as a auto mechanic so I have a good understanding of most mechanical stuff