ATHENA Fork Oil Seal Kit 35x48x10.5 mm for KAWASAKI, YAMAHA, HONDA and SUZUKI 1969-1991

The ATHENA 35x48x10.5 mm P40FORK455031 fork oil seal kit is designed for YAMAHA IT 125, XT 250, YZ 100, KAWASAKI KL 250, KX 80, KX 250, HONDA XL 250 and SUZUKI TS 250 from 1969 to 1991. The fork oil seal keeps the oil inside the fork leg while letting the inner tube slide. It is a wear item: dust, mud and impacts on the tubes eventually damage its lip, and the fork leaks.

Specifications

• Brand: ATHENA
• Manufacturer part number: P40FORK455031
• EAN code: 8055681307780
• Weight: 50 g

When to replace it?

• Film of oil on the inner tube after a few fork strokes.
• Oil traces on the fork leg, the caliper or the brake disc.
• Fork that becomes softer on one side.

Before replacing a leaking seal, clean under its lip: a trapped grain of sand is sometimes enough to cause the leak. If it still leaks, replace the seals on both legs. Measure your seal (inside diameter, outside diameter and height) or check the original part number: the size is in the name.

Fitting tips

1. Drain and disassemble the fork leg following the manual, then remove the dust seal, the circlip and the old seal.
2. Check the fork bushings and the condition of the inner tube: a scratch or a rust spot will cut a new seal.
3. Protect the end of the tube (plastic bag), oil the lip and drive the seal in straight with a seal driver of the right diameter.
4. Refit the circlip and a new dust seal, then reset the fork oil level.

Why ATHENA?

Athena, an Italian company founded in 1973 near Vicenza, designs gaskets, pistons and cylinder kits for motorcycles. An OEM supplier to KTM, Ducati, Fantic, Piaggio and Triumph and a partner of the MXGP world championship, it develops its parts on the test bench and on the track with racing teams.

Spare parts and items to plan

• Fork dust seals : ATHENA P40FORK455098 · ATHENA P40FORK455131
• Fork oil : LIQUI MOLY 10W 500 ml
• Fork bushings : ATHENA · INNTECK

Frequently asked questions

Do I have to change both seals?
Yes: they have the same age and the same mileage. Replace both oil seals and, ideally, both dust seals.

Why is my new seal leaking?
Most often because of a scratched or pitted tube, a lip turned back during installation, or worn bushings that let the tube develop play.

Compatibility

Check the exact model and year of your bike in the list below before ordering.

Fits:
HONDA XL 250 1986
HONDA XL 250 1985
HONDA XL 250 1984
KAWASAKI KL 250 1979
KAWASAKI KL 250 1978
KAWASAKI KX 80 1991
KAWASAKI KX 80 1990
KAWASAKI KX 80 1989
KAWASAKI KX 80 1988
KAWASAKI KX 80 1987
KAWASAKI KX 80 1986
KAWASAKI KX 250 1975
KAWASAKI KX 250 1974
SUZUKI TS 250 1969
YAMAHA IT 125 1981
YAMAHA XT 250 1983
YAMAHA XT 250 1982
YAMAHA XT 250 1981
YAMAHA XT 250 1980
YAMAHA YZ 100 1981
YAMAHA YZ 100 1980