Fork seals still leak

proximity · Crazy Courier Joined: 08 Oct 2004 Karma :

My forks have been leaking for ages so i decided this weekend to sort them out. Took them apart, full clean inside, put the new seals in and put in the oil.

Went out for the first ride today and when i get back one of the fork legs is soaked, the seal has pissed oil out everywhere.

Why could this be? This is the leg that was leaking most before too, but there is no pitting on the fork leg so i dont understand why.
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2004 Aprilia Tuono

instigator · Super Spammer Joined: 19 Oct 2004 Karma :

You replace the fork and dust seal, yes?

Did you fill it up to the correct level (are you certain??)

And when you put everything back together, the seals sat flush against the fork leg? I could only guess that you either bought/were supplied with the wrong fork seals or fitted them incorrectly (best done with a slide hammer)

sickpup · Old Timer Joined: 21 Apr 2004 Karma :

Did you measure the fork leg for wear and inspect for damage?

Did you change the bushes?

Guest · Brolly Dolly Joined: 22 Apr 2004 Karma :

Did you fit the seal the right way round - spring towards the oil?

proximity · Crazy Courier Joined: 08 Oct 2004 Karma :

I fitted them the right way round, they are the correct seal and were a tight fit when i slid them on. I did both legs exactly the same yet only one leaks. No pitting or marks on it.

The only thing i can think i did wrong is i couldnt find any pipe to hit them in so i got 3 sticks of wood and place them around it and hit them one by one.
Also i didnt change the bushes but they looked fine to me.
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2004 Aprilia Tuono

sickpup · Old Timer Joined: 21 Apr 2004 Karma :

proximity · Crazy Courier Joined: 08 Oct 2004 Karma :

To be fair i dont know what i was looking for. They looked undamaged is what i mean, they were smooth and flush with the tube. Maybe they are knackered afterall.
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2004 Aprilia Tuono

instigator · Super Spammer Joined: 19 Oct 2004 Karma :

Sickpup - for future reference, what sort of wear and tear would you expect on the fork bushes? I presume from what you've just said, they just get "smaller"?

sickpup · Old Timer Joined: 21 Apr 2004 Karma :

I just replace them when I do the seals. Nice smooth fork action for an extra £8. Most shops won't warrant the work unless the bushes are done as well.

You can't really examine them it was a trick question. Wink

0.1mm of wear would probably cause problems.

mchaggis · World Chat Champion Joined: 09 May 2004 Karma :

The fork bushes are coppered steel, coated in teflon so far as I remember. Teflon coating wear is obvious as the copper shines through. It helps if they're both still circular and the lower bush (the one round the bottom of the stanchion) isn't squashed out of shape, as it is supposed to 'spring out' to fill the slider tube.

Another thing though, you're using the lower bushing as something of a slide hammer to drive the slider bushing out. That in itself can't do them much good.
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