250-500cc 2009 husky wr 300 fork seal replacement

hi guys im just about to change the fork seals on my 09 wr 300 and was wondering if anyone had a workshop manual download or a relevent file i could download with instructions ?

any help much appreciated

cheers jim

This thread has a lot of info on open and closed chamber forks... pick through it, and extract the info you need to point you in the right direction

http://www.cafehusky.com/threads/marzocchi-fork-bleed-dirtbike-magazine.3171/#post-44608

Just did mine a few weeks ago, pretty straight forward. Got the seal drivers from motion-pro, but just changed the seals and didn't do a complete tear down of the valve stacks. Will do that next time. Gerald at Upstate advised me to go with 140mm from the top for my oil, using 5wt. Good luck, have fun, save money...........

Here is a video part #1 of 3 that shows a fork (which is basically the same as the 50mm Zokes) being taken down and put back together. I recommend taking them all the way down so that you can clean the hard assembly grease out of the valving, unless that has already been done. It made a big difference on how my 09 WR250 Zokes worked. I made my own oil level tool with a plastic syringe from the feed store and you can use a wrap of electrical tape to protect the seal but the seal driver is a must. I bought mine from Motion Pro.

http://www.youtube.com/watch?v=W2G-b66F3es&feature=relmfu

What sort of seals are you all using, I have some Synergy seals on order and apparently they are the bees knees?

As a side note, mud or dirt can get in these seals and cause them to leak ... These seals are nothing more than a piece of rubber with a metal spring around them holding them tightly against the fork leg ... That's as low tech as it gets ... The rubber that rubs on the fork can wear down or maybe get a cut, but if that spring is on that seal, that seal may very well be OK but has dirt inside it and cleaning the dirt out will stop the leak...

Mine may leak after a mud ride ... I watch them a few rides and if the leak stays, I take the time to go inside the outer chamber, change the oil and clean the seals... To date, this has always stopped the leaks ...

It is probably a good idea to change that oil on a regular basis... I'm using ATF now in the outer tubes as I change the oil monthly or so ...