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thoughts - a leaky front fork help

H

hella_erika

New member
Joined
Jun 11, 2012
Location
east bay
Moto(s)
05 R6
92 CBR250RR
Name
Erika
Hi. I'm looking for thoughts/recommendations/ideas about a leaky front fork I have.

But first, I'd like to clarify something - I understand and have basic-good mechanical skills (if you'd like to call it that), but have very little knowledge about motorcycles in general. So please excuse any terminology or misunderstanding that I may have. I also don't know too many people who ride anymore..

Anyways, I do have one leaking front fork and I'm assuming the other one isn't far behind. I'd like to replace the seals and/or any bushings it may require. I watched a couple general YouTube videos, but haven't found one for my motorcycle.

I noticed that the fork tubes(?) have small rust spots, which I understand isn't good/ideal. But, how bad is bad? Are these tubes usable?

Also, is there a way to re-finish the lower fork legs(?)? Obviously spray cans won't last. I don't think they're powdercoated. I think I've read somewhere that they hard anodize the legs? Or is regular anodizing okay?

My intentions are weekend spirited riding and future track days.. On the fence on what to do. Or if I should send it out somewhere.

Anything helps, many thanks.



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I have used mini files to knock the rust off, and then polish the area. Held for years with no leaks.
 
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bikeama said:
Disclaimer I have not used one.

Sealmate Fork Seal Cleaner
Click to expand...

I have, but I doubt it'll fix this problem. The Sealmate can help weeping forks if the problem is caused by dirt sludge building up behind the sealing surface (lifting the seal lip off the tube). I'm guessing it won't help in this case. The rubber bits here look old/dry/brittle.
As for the tubes, it's possible to clean up minor tube damage with careful work but after you put it all back together it might just keep leaking. You won't know for sure until everything is apart, clean and examined under good light.
 
You can certainly powder coat the lower legs. As far as the tube, if the pits are deep you may be screwed. You can try to smooth the pits out but if they are big the seal will still leak. There used to be a company called " Forking by Frank" that made replacement tubes. Don't know if they are still in business.
 
The rust spots more than likely shredded the fork seals so the seals definitely need to be replaced.

The rust spots will also shred the new seals immediately.

The best option is to replace the fork tubes with new oem tubes.

If you can't afford that, the clean the rust spots off with chrome polish and/or very very fine steel wool (00 grade iirc).

Once the tubes are clean, check for nicks by running the edge/tip of your​ fingernail along the chrome surface. Anything that catches your fingernail will usually catch a seal and turn or tear the seal.

If you can't​ polish out all the rust spots, or there are significant divots left after rust removal, then the new seals will still leak.

I have yet to find a way to fill in the divots.

Once you have completed this fork service, keep the chrome parts clean and rust free by wiping them down at least once per week with furniture polish and a clean rag and the seals and chrome surface will last a lot longer.
 
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#1 Your 25 year old rubber cracked fork seals need replacing. Great opportunity to refresh with fresh fork oil when disassembled.

#2 Those rust spots need to be removed.

#3 Youtube certified mechanic diploma ain't gonna help.
 
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I had some spot rust on my 4 decade old Honda but it wasn't on the portion that was in contact with the seals. If there's no rust in the section where the leg travels it's ok. You can also get new legs from ebay or racetech.
 
u can prob find a set of forks in better condition on ebay for cheaper than doing all this work. those tubes might not be useable anymore which will necessitate ebay anyways.
 
Check to see if those rust spots actually reach the seals. If they don't reach then just sand them down with wet sand paper smooth.
If they do reach then replace them .

As for the lowers, its the clear that is pitting, and oxidizing . If your wanting to get the lowers redone shoot me a pm

Since your dust cover is cracking , replace both seals and you'll be good to go.
 
Replace the bushings while you're in there. They are probably shot.
 
as a temporary ghetto fix, wrap an old sock around the fork leg and zip tie, as a diaper , to keep fork oil from seeping onto your brakes.
 
I'd like to thank everyone for the help!! I REALLY appreciate it.

As for the Sealmate, it seems like a good idea. But I think my seals are a little too far gone for it though. I'm sure the other one isn't far behind either.

I didn't know if you could sand the tubes. I know that when chrome starts to pit, it gets flakey. But I'll give it a try with some 2000 grit and/or 0000 steel wool. Can't get any worse then now.. I think.

Dust shields will be replaced. If the bushings aren't too expensive and I can find them, I'll probably consider doing those at the same.

Rubbing down the tubes with something after the replacing the seal sounds like a great tip. Will keep that in mind.
 
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Buying new tubes would be ideal and I know the best solution. I guess I don't know where exactly to get them or another motorcycle model I can cross reference to. I'm hesitant to trust parts counter people lol (sorry, don't mean to be offensive). eBay doesn't list them for my model unfortunately.

Unless someone here knows what part # or model I can crossover to?! :D

Maybe I will call Racetech or Forking by Franks to see if they can come up with tubes. I don't mind having spare parts as it is an older bike.

I'm just anxious to ride the bike around. Haven't rode it before and I'm excited.
 
hella_erika said:
I didn't know if you could sand the tubes. I know that when chrome starts to pit, it gets flakey. But I'll give it a try with some 2000 grit and/or 0000 steel wool. Can't get any worse then now.. I think.
Click to expand...

This going to sound weird, but instead of sanding them, I've used a little ball of tinfoil that I dipped in H2O and rubbed it against the rust spots on forks, it works. Obviously it won't remove the pitting, but it will remove rust.
 
Probably any of the suspension shops in the Bay Area will be able to help. Also I'd check web sites specific to your bike. Sometimes there are others who have done a lot of ground work figuring out this stuff.

Keep looking on eBay. Usually when someone wrecks a bike the forks are one of the first things to be damaged. Unless you can find one with a blown engine. Salvage yards may be another source.

If you can adjust valves, for example, you'll be fine with forks. They aren't too complicated. That being said, I'd have a manual for the bike. But that's usually the first thing I buy after purchasing the bike. It's good to have.
 
seadog said:
Probably any of the suspension shops in the Bay Area will be able to help. Also I'd check web sites specific to your bike. Sometimes there are others who have done a lot of ground work figuring out this stuff.

Keep looking on eBay. Usually when someone wrecks a bike the forks are one of the first things to be damaged. Unless you can find one with a blown engine. Salvage yards may be another source.

If you can adjust valves, for example, you'll be fine with forks. They aren't too complicated. That being said, I'd have a manual for the bike. But that's usually the first thing I buy after purchasing the bike. It's good to have.
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Yeah. I've been looking at some other websites. But it sounds like the websites are EU or Austrailian based. Helps, but i don't know if foreign part # crossover here. Been keeping my eyes open on eBay. But again, parts across the sea. I imported the bike a couple months ago. Excited but nervous. I don't know too much about bikes, much less an aged bike. 😓

I've adjusted valves on older cars, but not on a motorcycle. The most I've done were spark plugs on an r6. My one motorcycle friend mentioned its not too hard. Maybe I'll give it a try and then have the bike inspected after I do a small tune up. Suggestions on somewhere? Definitely looking for a manual.

Many thanks
 
This is a long shot but if your fork tube diameter is 35mm it may use similar parts to the VTR250 which was imported into the US. Same time period and probably both are damper rod forks. Also the part number for the fork assy or fork tube from the Australian web site might help as the middle part of the part number, called the center code, identifies where the part was used first. So maybe was a model imported here. For example the VTR250 fork tube is 51410-KV0-671. So Honda fork tubes are 51410 and for VTR250 KV0 identifies the bike that tube goes to. Maybe the center code for yours matches something else imported here. Or if not but it is 35mm diameter possibly the tube from the VTR could be used or even a used set could be installed. New parts just not available other than bushings, bolts, seal kits etc. Like I said a long shot but could be worth a try. Honda has a book which identifies models to center codes which is helpful when trying to match parts. Good luck.
 
Found a site showing fork tubes are 37mm diameter so no dice on the VTR. But the early CBR600F was 37mm so thats another possibility. Don't know what shipping cost from Oz but if someone has a good set of tubes that would be best solution. Also if you get part number of seal kit from them as several Hondas use 37mm fork tubes so seal kit likely available here.
 
stever said:
Found a site showing fork tubes are 37mm diameter so no dice on the VTR. But the early CBR600F was 37mm so thats another possibility. Don't know what shipping cost from Oz but if someone has a good set of tubes that would be best solution. Also if you get part number of seal kit from them as several Hondas use 37mm fork tubes so seal kit likely available here.
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Thanks for looking into it. And yes, I think the tubes are 37mm and was able to cross reference some seals. I also emailed Race Tech about TNK tubes (which I think are good tubes?) and they actually had a pair in stock. $185/ea + tax + freight. I think their TNK catalog listed dimensions too :)

As of right now, I decided to pass on the tubes and refinishing the forks.. I decided to spend my money elsewhere and my funds for the bike were starting to get low. I figured for less then $50, it was worth to try changing the seals and see how they hold before spending $400 on tubes. It would also give me a chance to see how the condition of the rest of the parts are.

Plus I was getting anxious to ride the bike lol.
 
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