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Im in the process of fixing up my 03 burgman 400 and i have noticed that the round black doughnut looking seals on the forks are rusted..They seal the area where the "shiny" part of the fork slides in and out of the lower portion of the fork, and i'm assuming the two seals are there mainly to keep dirt and water from entering the fork, but do these seals also contain an oil down in the lower section?? I mean i know there is fork oil inside of there but i wasn't sure if these seals are the only ones holding the oil down in the shocks when they are compressed..Does anyone know how difficult it is to replace these seals? It appears as though the entire fork has to be disassembled... :( They are not rusted badly but you can see that its like a metal ring that is encased in rubber which makes the seal, and i can see the metal ring under the rubber is starting to rust and the rubber is cracking so i can see the rusty metal in certain spots. Is this a common failure on a burgman?
 

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I just purchased a 2008 Burgman 400 and my fork was leaking fluid yesterday. 2 mechanics saw the rust at the top of my fork & think that changing the seals won't be a permanent fix. The both think it needs a big job. My motorcycle instructor on the other hand says that the rust can be removed with some steal wool, soft sand paper or a plastic bag. What do you say?
 

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Hi 13bturbofc, fork seals are not hard to do. The seals you see on top of the fork sliders are dust seals, the oil seals sit lower down inside the fork and located by a spring clip and spacer. Replacement of course depends on your engineering abilities and available tools / skill level. so if replacing seals you have to strip them down, empty the old dirty oil, clean and reassemble adding seals and correct amount oil of course..

Have a look at this page and the advice / photos of my Y model Burgman having its seals changed. http://burgmanusa.com/forums/14-burgman-400-pre-2007/52809-fork-seals.htm

As for a common failure, all modern bikes that don't have fork gaters suffer the same issue. Stones chip the chromed stanchions, rust forms, seals get chewed. I fit simple plastic deflector held on with a cable tie to stop stones hitting the section of stanchion the fork lower leg moves over. ;)
 
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