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Date Posted: Wed March 07, 2007 11:03:40AM
Author: Rick in NYC
Subject: Leaking Front Fork Seal

It is snowing here in NY. Might as well work on the motorcycle!




My left fork seal leaks oil. I will be removing both forks to change the seals.



WARNING: FOLLOW INSTRUCTIONS IN REPAIR MANUAL CAREFULLY. THIS REPAIR INVOLVES RISK OF SERIOUS INJURY.
Place floor jack under engine. Use wood to spread the load. In addition, when working on the motorcycle with the front wheel removed, support the motorcycle in case the bike tips forward. If leaving the bike overnight on the jack, remember all jacks leak somewhat.



Remove cap from top of fork tube.



Use 12 mm swivel socket , loosen upper fork tube clamp.



Use 12 mm box wrench, loosen 2 nuts on lower tube clamp.



Remove 2 bolts holding brake caliper, and remove caliper from fork.




Unscrew speedometer drive cable. My cable dripped water, not a good thing.



On bottom of lower right fork, loosen 2 nuts.



Use 19 mm socket, remove large wheel nut.



Slide out large wheel bolt.




Remove spacer. On left side, remove speedometer drive gear assembly.



Jack up motorcycle. Front wheel then rolls forward.



Remove 4 nuts holding brace and fender.




It helps to spray the upper part of the tubes with WD-40, especially at the air hose connections. Twist and pull down the fork tube about 4 inches. You will then see a circle-clip that must be removed. Remove clip. The fork then can be removed all the way.



I used a 3 foot long pipe clamp tool to compress the spring. CAUTION: WEAR EYE PROTECTION !!!



Once the cap is pushed down about 3/4 of an inch, remove retaining circle clip.



Cap and coiled spring can now be removed.



Pour out old fork oil. I will be replacing the exact amount with 15 weight Belray brand fork oil.



Remove upper fork seal and lower seal retaining clip.



Remove leaking fork seal. Note, the seal is destroyed while removing it and cannot be reused.



I ordered new fork seal part # 92049-1363 from Carl Leo. Thanks Carl for your support. Coat seal with fork oil. I carefully pushed the seal into place with a large paint stirrer stick.



I had wanted to take apart the entire fork for thorough cleaning, but I could not. For disassembly, you need to remove the Allen head screw on the bottom of the fork. The previous owner must have used a lot of screw thread lock. I tried to use an Allen key, but stripped the screw head. I probably need an impact driver to remove the Allen screw.

For more tips see Gary Schill's excellent article on changing front springs at:

http://www.amervoyassoc.org/XIITipsWP.htm

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