Leaky fork seals

So I finally got my bike together this year only to find my fork seals we're leaking. .. again. I just replaced them last year (which sucked). I just noticed today, and I really don't want to take this apart again. I'm wondering if the fork air pressure would affect that? Because I haven't put the right pressure in yet, as I've just been test driving it. So I'm sure pressure is low because I had to take the forks off to replace my steering bearing.
Any thoughts as to why they are leaking again? Pitting or rust on the forks? There is a little but I didn't think it was substantial

Is there a way to clean out the dust seals without ruining them? I think debris and dust got in there from fixing my steering and I don't know how to get it out

 

lack of air won't make the seals leak but it doesn't take much rust or very big pits. The dust seals should just pull off, maybe a little heat gun to soften them.

 

Without taking the forks off the bike though. I heard of using something very thin like paper like, to slip in there and pull out debris or a solo cup or something, but a cup could get sharp so idk

 

they used to use the negatives from film cameras. They still make that stuff?
don't use paper or something that could break off in there

 

Just sucks cause this took forever to do and now it's leaking and im sure bringing it to a shop won't be cheap

 

And ok I'll look into that I'm not sure

 

You can cut a peice from a pop bottle to use as a seal cleaning tool. Just be sure to make clean cuts; no jagged edges. And carefully inspect the swept area of the upper tube for pits or nicks. They can be tended to without disassembling the fork, but the method will vary depending on how deep the damage is. Post up a pic so we can see.

What brand of seals did you get?

 

I'm not sure I just ordered OEM ones

 

Not sure if those help. You can kinda see the rust on the forks. None on the back side. And there's the leak

 

http://www.motorcyclecloseouts.com/...+accessories&gclid=CLj_gYnZkMYCFQYzaQodn5wAjA
Works nicely and can be had cheaper. My local aftermarket shop sells them for $15.00

 

I can see pitting that may have damaged the seal under hard breaking. Can you catch a fingernail on the lowest nick? Is it more than a hairsbreath deep?

 

Thats why I'm thinking the air pressure might have affected it, because the pitting is pretty high up. Maybe less pressure cause the fork bottoms to slide up higher and reach the pitting spots?

 

And I can probably catch a fingernail I'll check tonight. Because there was a tiny lows pot or 2

 

So if that's the case, think they are too far gone at this point?

 

You can fix them even if the pitting is deep. Step one is to clean out all of the rust with a pick. Step two is a thorough degreasing with carb cleaner. Step three is to fill the pits with a two part epoxy and allow it ti cure at least overnight (do not use a quick-setting epoxy; they are too soft). Step four is to polish the repair with increasingly fine finishing paper. I start with 800 and work my way up to 2500 grit wet-and-dry, using water on the papaer just as you would to wet-sand paint. Any shallow scratches should be polished out as well. This is effectively a permanent repair, but the epoxy will show.

 

Sweet I'll definitely try that. But I mean do you think there's hope left for those seals?

 

Oh no. If the seals are damaged they need to be replaced. Try cleaning any crud out from the seals first, and fix the nicks. You might get lucky and not need to replace them.

 

Ok. That soda bottle trick?

 

Otherwise maybe I can take the fork off myself and give it to a shop to fix, maybe that'll save money

 

Doing it yourself at home will save the most. It is easier the second time around. Yes the soda bottle trick. You want a hooked end to help bring any crud up above the seal.

 

Finally going to try cleaning those seals out. I made this from a Arizona Tea Carton and sanded all the edges. Someone online suggested.
I'm looking at the seals and any pitting thst would affect the Seals are 5" up from the top seal. And those don't look bad. The ones that would definitely affect the seals are about 6" up.. would they have gotten th

 

And I see guys prying the top seals up off the fork leg Pretty high to get in there but I can't get a screwdriver in there without wrecking the seals. It's tight

 

Here they are

 

Nevermind I got them up

 

Sorry for all the responses. Here's an inside pic. Oil sitting in there

 

There's your problem.


The chrome is scored, and I see a few small pits. Get to polishing that out as I described earlier. The final result should be mirror smooth. None of the pits in this photo (might just be dust I'm seeing) are deep enough to need epoxy.

I would reccomend a full fork teardown and rebuild as that sort of scoring is indicative of worn bushings. Further inspection is warranted.

 

Ok will do. I did what I could last night and went up and down a bunch of times on the forks and it doesn't seem to be leaking.. for now. Even earlier that night when I was doing that it would leak right away. I'm going to take it for a ride this Saturday see how it does, but I will probably end up doing what you said

 

And I'll definitely polish them first. I'm sure it may end up leaking down the road again Thanks for the help

 

Is that oil seal upside-down, and pulled out/unfolded?

Or at east it would be if it was on my '81 Seca 550!

Here's a pic of the one I just removed.
It installs with the "spring opening" down.

 

It is. Hopefully it can be removed and reinstalled without damaging the seal.
How the heck did I not notice that earlier? I must have been thinking it was a shot of the dust wiper and not seen the spring.

 

I've been looking, pondering and dreaming about mine all winter now!
Noticed right away!
Pouring in the 10w this w/e and sealing them up.

 

Shanesajda, ,
Did you do all your work with the tubes in?

There is an allen key bolt, in the the bottom of the lower fork assembly, that holds the upper tube via a tapered spindle and damper rod.
That makes it darn simple to remove the inner tubes and work on a work bench.

Just re-installed my forks, with all new seals and clips.
Works like a dream.

 

Since your seals are installed upside down the forks have to be removed so that they can be installed correctly. Oil seals are inexpensive, so I would order new seals from Chacal rather than try reusing those that you know have leaked. Even though you did this last year, you might want to look at my write-up with lots of pictures in the "How To" forum.