Leaking fork seal

[gonzo]

My left fork leg is leaking as I reassembled it incorrectly and had to take it apart again to put stuff in the correct order so from doing this the oil seal now leaks. Would I need to replace the bushes as well (they are brand new) but they have been disassembled (lower removed from upper)
Is there a way to change the oil seal without seperating the upper from the lower?
Thanks guys!

[Blaine]

Jun 28, 2013 21:18:20 GMT -6 gonzo said:

My left fork leg is leaking as I reassembled it incorrectly and had to take it apart again to put stuff in the correct order so from doing this the oil seal now leaks. Would I need to replace the bushes as well (they are brand new) but they have been disassembled (lower removed from upper)
Is there a way to change the oil seal without seperating the upper from the lower?
Thanks guys!

Sent you a P.m.

[gonzo]

Thanks mate :-)

[lamestlame]

Hey Gonzo if you don't mind me asking how did you go about installing the bushing's on the fork seal's?

[gonzo]

Remove front wheel, now the bike will sit back on center stand but put blocks under the frame (not under exhaust pipes Careful) remove mudguard. Remove air from fork, I found using 2 very small screwdrivers to prise out the top c clip easier than 1. 1 to move the clip out a bit then 1 to really carefully move it up. Have a 12mm socket with a long extention handle to push the top cap down wedged under your armpit as you do this as the spring will push it up but not real hard but with a bit of force. Actually bribe someone to help you with this as it can take a while. Now drain the oil from the bottom bolt behind lower fork. Come back in 10 min. Take the forks off and take out the inner top tube, washer and spring (messy) Remove the lower leg by the 6mm hex head with a impact driver (real fast) any bike shop worth there anything will do this for nothing. Now the lower will seperate from upper. Get some Brake and contact cleaner with Perchloroethylene in it (don't know if all cleaners have this in it but this stuff shreds built up scum. When you pull the legs apart now the bushes come out with them. The lower leg bush might need a removal tool (Oil and bearing remover 57001-1058)
MAKE DANG SURE YOU GET THE ORDER THEY COME OUT CORRECT film it and say out loud what order there in (I've fudged this and now have to do it again as I stuffed the seals removing them to fix it) Real carefully with a flat screw driver prise off the upper leg bush. Now stick it all back together, the top oil seal has the spring in it facing up (I got it down so I'm waiting on a new one Dang)
Have the bronze bushes face out or forward, not in any old direction. Once the lower leg is attached now put the top bush in the top of the lower leg then a washer then the oil seal. I think that's the correct order? Make a film of the removal and lay everything out in order on a bench. DO ONE LEG AT A TIME!!!
Use an impact again to put the bottom 6mm in again.
Don't tighten the mudguard till you've got the wheel on first. You have a torque wrench right! Do you have a manual, I'd be stuffed without mine.
There's a vid online of a kwak 750 fork change (same as ours)
Lastly be really REALLY careful how much force you tighten the oil plug bolt with.
65 in-lb only no more. Or you do what I did and then go up to the next larger bolt size as its now striped :-(doing)-:
Real easy job. Tons of info on this site of how to do it.
Good luck man :-)

[gonzo]

Use the old seal to push down on the new seal and get a pvc tube longer than the upper fork leg, thick walled and file it down so it fits inside the lower leg easily and gently hammer it down. Use some fork oil on the oil seal to move it easily.

[lamestlame]

Thanks much appreciated .