Front Fork Seals leaking

[smitty225]

Hey folks,

I'm in Laurel, Maryland.  My 96' B6 is leaking forks oil like a weeping baby.  I'm scared to ride the thing.  The shop where I had it inspected wants $300 bucks to fix.  I'm not adverse to wrenching myself, but I don't want to screw it up.  Would anyone like to walk me through tackling this repair?  I'd really appreciate it.  And if your local to me, I'd even through in a 6 pack of beer (if you imbib that is!) to make the time go by.

Also, the inspector told me I need to add side reflectors to the front and rear to pass inspection.  Where is the best place to order them?

Once again, all help would be appreciated!

Thanks,
Mike
 

[smooth operator]

I've done them but not often enough to go step by step without forgetting things off the top of my head. You'll need a vise, air impact to take of bolt in the bottom,laquer thinner(or type of degreeser) air  and compressor for blowing off and cleaning, clean rags. pan for draining oil and new fork oil to put back in along wih the new seals. This would be the time to chage springs if you were thinking of doing it.Are you with me so far,do you have a service manual?I did'nt check,but there might be  step by step instructions in the FAQ section.

[smooth operator]

I did'nt see anything in the FAQ in this forum. But I'm pretty sure there is in the BanditsRUS faq put up by Fast Larry.

[smitty225]

The mechanic says that If I bring him just the forks, he can do it for about $70.  Its that a good deal.  If so, how hard is it to just take off the fork?

[Red01]

Pretty easy.

You will need to find some way of supporting the bike while the forks are off. Either a front end stan that goes in thru the bottom of the steering head, or support at the front of the frame (or ening in the case of a 400/250).

Remove the front wheel.
Don't let the caliper(s) hang by the hose.
Remove the front fender.
Loosen the pinch bolts on the upper & lower triple clamps.
Slide the fork tubes out.

[smitty225]

Thanks Paul.  

Can I put it on the center stand and then use a car jack to prop up the front (so the weight is shifted backwards)?

Mike

[Red01]

Sure... as long as that jack doesn't leak down while you have the front end apart.
I've used the jack to get the wheel off, then slid a jackstand under the frame in case the jack looses pressure.

[smitty225]

Cool.  I'll try it tomorrow nite.

Mike

[smitty225]

Everything was going well.  I was actually surprised at how easily things came apart....until I tried to remove the front axel.  It wont budge.  What tool should I be using to turn this baby without stripping it?  I don't have the original tool kit that came with the bike....and I couldn't find the size of the bolt in the Clymer Manuel I have.  Do I have to use an impact hammer to turn it?  Any help appreciated.

Mike

PS.  Everything else is loose and the forks have even slid down from the whatever you call them that holds them on the bike.

[Red01]

Did you loosen the pinch bolts (#16 below) for the front axle?

[smitty225]

Yep.  They are loose.

Mike

[smooth operator]

Take the pinch bolts out and I think its a 24mm(if not its a 22mm) on the axel. It tightens down, but you should be able to just take it out with a 1/2" drive ratchet.

[smitty225]

Thanks.  I'll try it tonite.

Mike

[tacoman]

Try a little penetrating oil too.  Sometimes a little corrosion gets in there and acts like loctite.

[smitty225]

I stopped at Advanced Auto, picked up a metric wrench set.  The axle came off like it was greased.  

So, it looks like this is a repair I'll be able to do.  I ordered a set of progressive springs, and some fork seals from Holeshot.  Should be here next week.  

I'll let everyone know how things go.

Mike