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Discussion Starter #1
My buddy Mike and I replaced the fork seals on his '90 CBR600 almost a year ago, though he has only logged about 600 miles since then. Recently, the fork seals began leaking again, though it is not apparent where exactly from.

Could the forks be bent?
Could the shocks have bottomed out and damaged the new seals?

Everything looked to be in good condition when we had it apart the first time, and we were careful to not damage any of the interior surfaces during reassembly. The only other thing that comes to mind is that we used a piece of PVC pipe to install the new seals as opposed to the "official" Honda tool (as recommended by the Clymer manual). I really don't think that we could've damaged the seals that way though, judging by how well the pipe fit to the Outer Diameter of the seal.

Some direction here would be greatly appreciated!!!
 

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If you are blowing the seal that quick, your best be would be the inside fork tube is damaged. Most likely possibility is pitting or scratching, but also check wear. If it is neither of them that is a problem, then they may be bent.
 

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A buddy had a similar problem blowing fork seals on one fork. Turned out he has a very small scratch on the fork, so small you couldn't even see it, but you could feel it if you dragged your fingernail over it. We buffed it out with some jeweler's rouge and a felt buff on a die grinder, and it has been fine for a couple years now.
But if BOTH of his are leaking, chances are you put them in wrong or damaged them during the install. It seem highly unlikely to me that both forks are damaged or corroded in such a way as to make both fork seals start leaking at exactly the same time.
 

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I was going through fork seals about once a year. They dry out quite quickly in Arizona. Especially when they sit for long periods of time. Also, if there was dirt or anything on the fork tube when you replaced the seals, that will cause pitting and wear on the seal as well.
 

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Good point intimid8er. How's the guy ride? If he's really gouging I'd say that might be the problem. Bend or damaged fork tubes are definitely a possibility, but if both are leaking it's probably the install.
 

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Discussion Starter #7
Alright, after posting in this forum and another, Mike and I have deducted that although we replaced the oil seal (non-OEM) and dust caps, we did NOT replace the bushing!

We'll take extra care to inspect the forks and ensure that they're dirt-free upon installation.

Thanks for the input everyone.
 

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Alright, after posting in this forum and another, Mike and I have deducted that although we replaced the oil seal (non-OEM) and dust caps, we did NOT replace the bushing!

We'll take extra care to inspect the forks and ensure that they're dirt-free upon installation.

Thanks for the input everyone.
Also check for pitting. Use a light touch and go over the fork tubes where the seal slide and see if there is any roughness. If there is and it isn't to bad they can be cleaned up.
 

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Or just use cement in the forks, never have to worry about em leaking again, and you'd get a nice firm ride
 

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Discussion Starter #12
Or just use cement in the forks, never have to worry about em leaking again, and you'd get a nice firm ride
That's a great idea. We tried duct tape and it really didn't work too well...
 

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That's a great idea. We tried duct tape and it really didn't work too well...

Actually, now that I think about it, it also depend on what brand of seals you get. Some of the off brands are pretty crappy
 
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