New Fork Seals Leaking - Yamaha FJR Forum : Yamaha FJR Owners Forums
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post #1 of 23 (permalink) Old 11-13-2016, 12:11 PM Thread Starter
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Thumbs down New Fork Seals Leaking

2007 Yamaha FJR1300A.

Hi Guys.

I need a little advise from the collective wisdom please.

A month or so ago I noticed a weep from one of my fork seals so having done a few seals myself in the past I decided I would carry out the job myself replacing both seals and bushes, after doing much reading and research from the forum her all went relatively well, the middle bush was a chore but I got it done.

I've done about 100 miles and have noticed that both appear to be leaking now, what's going on.
Both fork legs are in good condition with no damage.

The seals were greased and care was taken to protect the new seals when being slid onto the stanchions tubes.

I hope you guys may have some ideas what may have gone wrong.

Many Thanks.

Yamaha FJR1300A 2007
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post #2 of 23 (permalink) Old 11-13-2016, 02:40 PM
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Many years ago I had a problem like this on a FJ1200, new seals would leak almost immediately. Turned out the oil was getting out passed the outside of the seals, not the inside as you would expect. A mechanic friend advised me to glue the new seals into position with a special Loctite solution. That was it, problem fixed.
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post #3 of 23 (permalink) Old 11-13-2016, 06:14 PM
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Did you check out the fork legs for micro scratches.
Need a good touch or outside in good light.
Had exactly same problem . Managed to polish them out with Autosol metal polish.
make sure no debris in the dust seal scratching the legs.

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post #4 of 23 (permalink) Old 11-13-2016, 07:40 PM
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Originally Posted by Cozza View Post
2007 Yamaha FJR1300A.

Hi Guys.

I need a little advise from the collective wisdom please.

A month or so ago I noticed a weep from one of my fork seals so having done a few seals myself in the past I decided I would carry out the job myself replacing both seals and bushes, after doing much reading and research from the forum her all went relatively well, the middle bush was a chore but I got it done.

I've done about 100 miles and have noticed that both appear to be leaking now, what's going on.
Both fork legs are in good condition with no damage.

The seals were greased and care was taken to protect the new seals when being slid onto the stanchions tubes.

I hope you guys may have some ideas what may have gone wrong.

Many Thanks.


when reassembled
its possible to pressurize the forks

if reassembled / filled w fluid while extended
when capped & the weight of the bike can pressurize the forks

conversely [ tho Unlikely ] reassembled ..... forks compressed they could have a vaccum
drag racers have done thusly so to plant the front end
now they use a strap

you are going to have to do it again
careful observation on disassembly might reveal the culprit
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post #5 of 23 (permalink) Old 11-13-2016, 09:30 PM
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My first question is about fork oil level. Did you set it with springs out, inner fork tube all the way down, measure fork oil level to the top of the tube = 100 mm? Next did you install the seals upside down?
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post #6 of 23 (permalink) Old 11-14-2016, 06:43 AM Thread Starter
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New Fork Seals Leaking

Hi Guys,

Thanks for the replies, I was very careful and followed instructions that I had printed out.

The fork legs are good and blemish and scratch free so I cant see this being the problem, the seals & bushes were all fitted, the fork tube pushed right down in the lower leg and the spring was fitted, I measured from the top of the tube down 100mm and the oil was just touching the measure.

I've contacted the supplier who are now looking into it as when the kit was supplied there was no middle bush present so this had to be re used.
I was very careful and covered the top of the fork tube with a plastic bag to prevent any sharp edges damaging the seal when fitted and the seals were well lubricated with the supplied grease.

It's just such a pain to possibly have to do it all again DOH!

Yamaha FJR1300A 2007
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post #7 of 23 (permalink) Old 11-14-2016, 07:13 AM
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Sounds good. Then my next recommendation before tearing it all down again is to take a Sealmate type tool and clean around the seals. Lift the dust seals out and slide them up the tube. You can make one from thin plastic or 35mm film or milk jug material.... perhaps the grease (I use fork oil to lube) just needs some time to clear so there is a good contact surface? They should not "leak", which I would define as oil running onto the dust seal that keeps returning after you have wiped down the tubes and seals. So, the other thing to do is to wipe all residual oil off with some rubbing alcohol to ensure the oil you saw was not just residual oil. Once the forks have been jounced, a very slight oil film should be on the tubes, which is perfectly normal.

On the FJR, the seals go in with significant enough interference fit that they should not leak on the outer diameter, and the only way I can see they would leak at the inner diameter is if they were damaged/nicked. I'd just try cleaning them up first before deciding if they're really "leaking". If you could take a picture of the top of the seal while you have the dust seals up, I might be able to tell if they are right side up... what did their instructions tell you about orientation?
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post #8 of 23 (permalink) Old 11-14-2016, 08:53 AM
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How did you install the seals? A good seal driver keeps them square in the bore, and won't tweak the seal housing when installing. I've seen some hack jobs come into my shop with seals bent so bad from a punch or a screwdriver, I just smh. Not saying you hacked your seal job, just saying.
I would try cleaning the grease out of the seal with a seal saver type of tool like RaYzerman suggests. You can make one yourself out of a thin plastic sheet. Once you get it cut out, be sure to de-burr the edges with 600 or finer sand paper. You don't want to ruin your new seals with a sharp object inside the seal. A milk jug seems too thick, and stiff to get the job done, but I can't say because I never used one. A plastic 2L soda bottle will work fine.
FWIW, one seal on my '04 was leaking when I got it a few months back. I made a seal saver tool, cleaned it out and it hasn't leaked since.
And a pic would tell us what's "up". Good luck.
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post #9 of 23 (permalink) Old 11-14-2016, 11:04 AM
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Are you using a factory service manual? Am I mis-reading? Perhaps a difference in The Isles vs. The Colonies?

My FSM says tubes compressed, no spring installed, 92 mm from top.

Russ
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post #10 of 23 (permalink) Old 11-14-2016, 04:45 PM
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There are some You Tube videos on how to use the Seal Mate and its clones. One of the things they tell you to do is to rapidly compress the forks a few times to set the seals. It may work for you to do this step first to see if it works. Sit on bike, feet on the ground, hold front brake and use your body weight to compress the forks. Little to lose in trying the Seal Mate and/or the compression.

Kevin
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