Motorcycle Repair/Fork seals

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Question
QUESTION: Hi, have an 88 kawasaki vulcan vn1500 se b2 i changed fork seals dost seals and oil followed clymer rep man to the letter forks are still leaking any ideas or suggestions? Thanks

ANSWER: Hello Jim,

Assuming that all spares used are correct, and all done properly, check the fork inner tubes for
dents and scars.
If you give me the VIN of the bike, I can check for the part numbers should been used, for you to
verify.
If the description is accurate though, the part numbers are: 92049-1363 Oil seal and 92093-1268 outer seal.

Best Regards,
Lazaros.

---------- FOLLOW-UP ----------

QUESTION: Thank you yes part numbers are correct inner tubes are like new no bad spots

Answer
Hello Jim,

Sorry for the delay, but I was trying to find the Clymer manual, to check for mistakes or inaccuracies. Wasn't able to find it.
The only thing I can do is specify the reasons that can lead to oil leakage.

a)Damaged oil seals. This also refers to installation error. If we knew we did something wrong, we wouldn't do it in the first place, right?

b)Damaged inner tube surface. It's a common issue, the tubes be O.K., but due to wrong tools used for seal installation, dents and/or scars are done, below the outer seal and non-visible unless removed again.

c)Excessive bushing wear, thus tolerances that oil seals can't compensate.
Lift the front of the bike and check fork lower tubes for excessive play back and forth.

d)Too much oil in the forks. Check oil level. 140mm from oil surface to top of inner tube, with forks fully compressed, without springs.

Do not rely on previous inspections. Check everything again.
Remember that, on mechanics, everything is faulty unless proved correct!!!

Best Regards,
Lazaros.  

Motorcycle Repair

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Lazaros Ampatzidis

Expertise

I can help you on EVERY issue involving POST-1980 Japanese Motorcycles plus KTM and Husaberg. My field of expertise includes Engine, Transmission, Fuel system (carburation & EFI),Electrics and Electronics. Maintenance, repair and tuning. Road and off-road suspension tuning. Please don't ask me about non-Japanese Motorcycle, especially American built on which I have low to zero experience.

Experience

I'm a rider and hobbyist since childhood. 25 years motorcycle workshop mechanic.15 years motorcycle racing mechanic. In order of experience high to low:Kawasaki,Suzuki,Honda,Yamaha,KTM,Husaberg.

Education/Credentials
Hellenic (Greek) Technical School.Internal Combustion Engines Engineer. Automotive Electronics.

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