Synergy seals in *********** 50mm forks (1997)

I am having difficulty installing Synergy fork seals in my *********** 50mm forks http://www.synergyseals.com/.

Has anyone used these fork seals before?

If installed with the U-Grovve down they seem a little large and won't seat in the fork leg.
They would go in with the groove facing up but I am pretty sure that would be the wrong way.

They give you a plastic strip which is supposedly needed for the install (see picture) but I cannot figure out how this is to aid installation?

I have the fork seal installation driver but it does not work with these seals.

Also the seals are not as thick as the stock seals and wonder how this will affect things?
PLastic strip:


U groove facing down, extra plastic spacer that actually goes on top of the seal:



U-Groove facing up. The seal would install this way but I don't think that would be correct.

schultzy said:

I replaced the seals in my 98 600 last year with seals from Dan. I was expecting difficulty and a snug fit when I slid them over the fork leg and into place but they seemed too large and slid into place easily. I have to wonder if they were the right size.
Yes, they leak slightly.
I would be interested in your outcome!

Click to expand...

Did you need to use the plastic seal protector?

I have tried to use the plastic strip as described by tirebiter but again the seal seems too large in diameter, so when the you try to push the seal down into the lower fork with the strip thing in the lower fork leg there is just no room.

I think I am going to try putting the seals in the freezer for awhile to hopefully shrink and firm them up a bit as they are very soft making a seal driver useless with these seals.

I suppose there is a reason that these are the old style seals.

Johnf3 said:

husabutt said:

schultzy said:

I replaced the seals in my 98 600 last year with seals from Dan. I was expecting difficulty and a snug fit when I slid them over the fork leg and into place but they seemed too large and slid into place easily. I have to wonder if they were the right size.
Yes, they leak slightly.
I would be interested in your outcome!

Click to expand...

Did you need to use the plastic seal protector?

I have tried to use the plastic strip as described by tirebiter but again the seal seems too large in diameter, so when the you try to push the seal down into the lower fork with the strip thing in the lower fork leg there is just no room.

I think I am going to try putting the seals in the freezer for awhile to hopefully shrink and firm them up a bit as they are very soft making a seal driver useless with these seals.

I suppose there is a reason that these are the old style seals.

Click to expand...

The plastic strip deals are a pain. The outside of the seal can be damaged by the groove where the circlip goes, if it is sharp. The plastic is intended to protect from this. If it is not sharp, don't use the plastic. It will make the install way easier.

I have installed a few sets of these old style seals, and they aren't too bad. Use something wide and flat to push in the seals--they will go.

Click to expand...

I finally got it after fumbling for a long time. I could not install the seals without the seal strip because the seal would hang up in the groove. Finding the right "seal pusher" as you described is essential. I have an old screw driver with the edges smoothed which worked good. I still used a Race Tech seal driver to finish tapping it in. I was able to do the second fork leg in just a few minutes. Talk about learning curve.

Thanks for all of the help. I was ready to order a stock seal set but now think these may be good.