Replacing the fork seals on a 94 Magna

Easy one man job until you start to put the spring back in. OK, here we go...

1. Remove the fender (Allen wrench)
2. Remove the brake caliper (12 mm wrench)
3. Remove the 4 bolts in the lower forks (12 mm wrench)
4. Remove the drain bolt on the back of both forks and drain the oil (10 mm wrench)
5. Remove the big nut on the axle (crescent wrench)
6. Put a small screw driver in the other side of the axle and remove axle and wheel
7. In the bottom of the forks is a 6mm Allen bolt. Remove this with an impact wrench so the inside will not turn
8. Take a small screw driver, slip it under the dust seal and loosen it
9. Slide dust seals up the fork out of the way
10. With a small screw driver remove the lock snap ring above seal
11. Remove the cap on top of both forks (17 mm wrench). This takes a lot of force to catch cap, spring is under it. Do not be afraid.
12. Remove sleeve, washers and spring. Lay them in order so to replace in same order
13. on bottom half of forks, part that slides,,with about 40 pounds of force,,pull down fast and seal will come out
14. Remove all parts in order so you can put them back in same order
15. Put the new dust seal, new seal, washer and bushing back in order they came off
16. Slide fork back together and put 6mm Allen bolt back in bottom
17. Take a piece of 2" plastic pipe 6" long and split it in half
18. Wrap the plastic pipe around the fork above the seal and put a radiator clamp on the bottom of the pipe. Tighten until the pipe has the same curve as the fork and fits on top of seal
19. Have one person hold the pipe in place while you take a 12" piece of wood. Lay it on top of the pipe and hit with a hammer; rotate and continue until the snap ring fits in place
20. Put all parts back in the top as they came out, and pour in 17.62 ounces of transmission fluid
21. Take a speed handle and a 17mm 6 point socket. Have someone guide the washer and cap while you push down hard and tighten. Do not cross the threads
22. Replace fender
23. Replace the wheel and axle.
24. Take a large screw driver and put between brake pads and pry them apart a little. Remount the caliper
25. Do not forget to use the front brake a few times to pump back up

    This job took me and another guy to which neithe had ever done it before, 1hour and 30 minutes total

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    Thanks to Freddie Dobbs