Forks leaking...help!
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Road Master
Joined: Sep 2011
Posts: 1,231
Likes: 32
From: Long Island, NY
Forks leaking...help!
Hey everyone,
Over the winter, I removed, powder coated, and reinstalled my lower fork legs. When I re-built the forks, I used all new seals. I followed the HD manual to every last detail, but recently when I went for a ride, I noticed that there was some type of oil on the top of the highway bar, on the front of the rocker box on the front of the engine, on my fender, on the lower fork legs, and on the brake calipers. I checked the fork caps, and they were dry. I also checked the drain screws and the bolts on the bottom of the forks and they were dry too, so it looks like it's leaking from the seals. I cleaned it all off and started bouncing pretty hard on the front suspension, and it didn't look like I could make any more leak out, but still, I am sure this issue is still going to occur. I've resigned myself to the fact that I'll need to disassemble the forks...again, and rebuild them with new seals, but my question is, do you think it's sufficient to just install the new rubber seals (the one with the spring in it)? I feel like since they're brand new, and installed in the correct orientation, they shouldn't be leaking. Is there something else I might be missing here?
Thanks in advance for any help.
Over the winter, I removed, powder coated, and reinstalled my lower fork legs. When I re-built the forks, I used all new seals. I followed the HD manual to every last detail, but recently when I went for a ride, I noticed that there was some type of oil on the top of the highway bar, on the front of the rocker box on the front of the engine, on my fender, on the lower fork legs, and on the brake calipers. I checked the fork caps, and they were dry. I also checked the drain screws and the bolts on the bottom of the forks and they were dry too, so it looks like it's leaking from the seals. I cleaned it all off and started bouncing pretty hard on the front suspension, and it didn't look like I could make any more leak out, but still, I am sure this issue is still going to occur. I've resigned myself to the fact that I'll need to disassemble the forks...again, and rebuild them with new seals, but my question is, do you think it's sufficient to just install the new rubber seals (the one with the spring in it)? I feel like since they're brand new, and installed in the correct orientation, they shouldn't be leaking. Is there something else I might be missing here?
Thanks in advance for any help.
Road Warrior
Joined: Sep 2005
Posts: 1,569
Likes: 12
From: Arizona
if you made sure the bushings were good, tight, then the seals shouldn't be leaking. i know a few people that did there seals and the bushings inside the lower tubes were bad, loose, and all they did was leak.
Banned
Joined: Apr 2008
Posts: 2,492
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I know you guys are having some warmer weather, lucky dogs......Any chance it's neck bearing grease getting hot and blowing around? It will separate when hot, and pool up on the lower tree then blow all over stuff.
Mark
Mark
Thread Starter
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Road Master
Joined: Sep 2011
Posts: 1,231
Likes: 32
From: Long Island, NY
I had read someone mention this before, but I never had this issue before in warm weather, and I haven't greased the neck bearing since I've owned the bike, so it wouldn't have any extra grease.
Thread Starter
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Road Master
Joined: Sep 2011
Posts: 1,231
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From: Long Island, NY
Alright, thanks guys. I'll check it out. When you say a "nick", I mean are we talking like a scratch big enough to be felt with a finger nail? I'll double check that.
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Road Warrior
Joined: Sep 2008
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[QUOTE=mglax13;9672397]Alright, thanks guys. I'll check it out. When you say a "nick", I mean are we talking like a scratch big enough to be felt with a finger nail? I'll double check thatscra/QUOTE]
Yes, you could barely feel it. It looked like they sratched it when removing the old seal. I took them back and they changed the seals again. Installed them back on the bike... leaked again. So I took them apart and found the nick. Bought a seal installer, new seals, and new fork tube. Did it myself. No more leak. It might be worth checking yours. I went crazy trying to find the leak. Checked everything you did and then some. Airlines, caps, tried teflon tape, etc.
Yes, you could barely feel it. It looked like they sratched it when removing the old seal. I took them back and they changed the seals again. Installed them back on the bike... leaked again. So I took them apart and found the nick. Bought a seal installer, new seals, and new fork tube. Did it myself. No more leak. It might be worth checking yours. I went crazy trying to find the leak. Checked everything you did and then some. Airlines, caps, tried teflon tape, etc.
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Joined: Jun 2010
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From: Moline, IL
make sure you get it all cleaned up really good and see if it was just a small amount that spilled when you filled them back up. i had the same problem last week. i did my first 50 miles after installling new forks and it was ok but then i saw some fluid after the next 100 or so, wiped it all up and checked everything and it turned out i did spill tiny bit while fillin them and it looked like a lot more than actual
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Road Master
Joined: Sep 2011
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From: Long Island, NY
Ok, I took both forks apart and very closely inspected the tubes. They feel smooth as glass. I can't see or feel a single nick on the things. I guess I'll try new seals and slider bushings. Could I maybe be messing up the seals when installing them with the PVC pipe? I know other people have done it, but maybe I'm screwing something up. I mean the PVC pipe is REALLY tight to the fork tube, so maybe it's screwing up the seal somehow. Anyone around the Long Island, NY area have one of those slide hammer tools they use to drive these home?
Also, there are 2 sides to the seal. I can see a spring on both sides. On side though has some writing, and the space in the middle is slightly smaller. The other side has no writing, and the space in the middle is larger. Which side goes up, and which side goes in towards the lower part of the fork?
Thanks.
Also, there are 2 sides to the seal. I can see a spring on both sides. On side though has some writing, and the space in the middle is slightly smaller. The other side has no writing, and the space in the middle is larger. Which side goes up, and which side goes in towards the lower part of the fork?
Thanks.
Last edited by mglax13; Apr 16, 2012 at 06:25 PM.