Hi,
Replacing fork seals on my 05 DL1000. Started w/the right side, the leaky side and that went easy-peasy.

I figured I should do both, so I took apart the left side to replace it today. Everything came apart OK, but when I went to reinstall the inner fork into the outer fork, I realized there wasn't enough room to get the new seal in so I could install the metal O-Ring above the oil seal.

So I pulled the inner fork out of the outer and noticed that the slide bush wasn't seating into the lower fork - not one bit. I even bought a new one with the new seals just in case, but the new one won't slide in at all into the lower fork.

When I first bought my DL last year I remember someone posted something about how to fix this but I can't find it.

I guess I got really lucky on the first fork because everything just slid in and all I had to really worry about was setting the oil seal properly.

Has anyone gone though this and if so how did you slide that thang in !

TIA

Maybe the video on the Wee may be of help to you https://www.stromtrooper.com/dl650-d...ork-seals.html. Have you googled "DL1000 fork seal replacement + video"?

Google black lab fork-seal replacement as well. Really good write up and picture. My dust covers are cracked but no leaking so far. I’d probably install heavier springs when I do it, I get a lot of break dive.

Thanks! I think the black lab site was the one I saw last year but forgot to bookmark. I appreciate all of your responses! I ended up just using the PVC (split so it'd fit) to push down the bushing - with the big washer on top of the bushing. I'll be glad to have this done! New Metzler front tire, new front pads because the fork oil leaked onto the right pads. After this I'm going to have to take the tank off since it looks like I have a slight coolant leak on the top of the engine. I see a tried 'trail' of what I'm pretty sure is coolant, but it's not a fast leak.

Thanks again for the help.