2003 BMW F650CS Fork seal replacement

About $75 US for everything as of June, 2022.
New seal kit from Amazon for $40
Fork Oil for $14 (10W)
O-rings for caps (400pc set) $8. Only used 2.
Fence clamps (2 pack from Amazon) $12. Only used 1.
Radiator hose clamp $2 (I had a spare)
Reused the drain bolt washers (BMW shop did not have them in stock and would take over a week to get). No leaks so far.
Links:
F650CS Wiki:
f650cs.wikidot....
Fork seals:
All Balls Racing 56-161 Fork and Dust Seal Kit a.co/d/iGiAK5o
Fence clamp:
Milescraft 4009 FenceClamps- Universal,Silver a.co/d/441EJWa
Fork oil: (I got mine from cycle gear locally)
Maxima 55901 10WT Standard Hydraulic Fork Oil - 1 Liter Bottle , BLACK a.co/d/fytKi6y

[@geoffreypinchen5075]

Thank you for a really clear and comprehensive guide. Excellent! I intend to follow it when I service my forks this winter. Did you consider fitting fork gaiters/rubber bellows, the type that used to be seen on most motorcycles until 1970's and fashions changed. They are still used on motocross bikes and really do prevent dirt and grime from damaging the stanchions and the seals. I bought a set on Aliexpress for just a few £'s/$'s and shall be fitting them during stripdown and hopefully will not need to touch the forks again!

[@gingerbard2607]

When I've replaced seals on other bikes I haven't needed to take of the difficult top cap - I've just released the bottom screw and separated the two halves.

[@hackjobrepairs8938]

Interesting, this was my first time so I did it by the book, we’re you able to get the correct amount of oil added that way?

[@gingerbard2607]

@@hackjobrepairs8938 Yes, just poured it in through the bottom before replacing the Allan screw.

[@calebmcinturff]

For the record, that bushing was smoked. Replace it if it looks like that next time.

[@TulaneAve]

You can skip the trick with the tape if you use the right size piece of PVC pipe and fitting as I do. Only takes some light tapping to seat these seals.

[@hackjobrepairs8938]

I tried but was not able to find the right size pipe… but with the tape it’s a lot easier to customize your size. 😀

[@artemmag244]

Сальники ставятся пружинкой к маслу!!!