SuzukiSavage.com - Leaking fork seal revisited.

och Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 640	Re: Leaking fork seal revisited. Reply #15 - 12/05/24 at 12:03:15 Found some old photos from when the original fork seal started leaking. From what I can tell, there was no scratch on the tube, so the mechanic who did the job must have scratched it.
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ThumperPaul Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2211 Houston, Texas Gender:	Re: Leaking fork seal revisited. Reply #16 - 12/06/24 at 10:30:26 Need bigger pics! LOL. You gotta quit riding on those salty nothern roads.
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Ruttly

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Re: Leaking fork seal revisited.
Reply #17 - 12/06/24 at 23:38:17

Dats ugly. Most forks are easy , the more dampening adjustments the more complicated. Just makes it more of a challenge. I like rebuilding the fork once it’s off the bike ,the rest of the job is just time consuming and it ties up the bike too. Savage requires special tool , can be made with welder. Length of pipe with a nut welded one the end.

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Surviving Philly

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Re: Leaking fork seal revisited.
Reply #18 - 12/09/24 at 05:39:12

You can make it without a welder also. There's a thread on it kicking around somewhere -- trying to remember as I only did this job once. I vaguely remember getting a long section of threaded rod with two nuts on the end that can crack the internal bolt and then a section of PVC that fit snugly in the tube ... Something like that.

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Ruttly Serious Thumper Offline Thumpers Rule Posts: 5414 Manteca , CA Gender:	Re: Leaking fork seal revisited. Reply #19 - 12/09/24 at 17:33:26 Tool was only used for holding dampning rod while Allen bolt is removed and installed. They are hella tight from the factory. After that it’s easy.
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och

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Re: Leaking fork seal revisited.
Reply #20 - 02/23/25 at 11:39:47

Warmer day today, so I decided to work on that leak. The bike has been sitting all winter untouched. I checked it out, the seal was completely dry, which makes me think it only leaks in the summer when the hot weather makes the fluid expand?

Either way, I sanded down the scratch, but I think I sanded it to the bare metal. Looks like the tube is chrome plated, I sanded down a spot of of the scratch to bare steel, so now it is going to rust.

Eventually I'll just have to replace the tube.

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och Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 640	Re: Leaking fork seal revisited. Reply #21 - 06/10/25 at 19:05:11 So far its holding up.
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Gary_in_NJ Serious Thumper Offline LS650 Cafe Racer Posts: 2651 Amongst the Twisty Roads	Re: Leaking fork seal revisited. Reply #22 - 06/11/25 at 05:35:44 You can remove the scratch. I would use a cleaning fluid like WD-40 and rub the scratch with 1000g or higher sandpaper, and then polish it wet (WD-40 again) with 000 Steel Wool. I've done this many times and it has never failed.
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Re: Leaking fork seal revisited.
Reply #23 - 06/13/25 at 08:34:56

och wrote on 02/23/25 at 11:39:47:

Warmer day today, so I decided to work on that leak. The bike has been sitting all winter untouched. I checked it out, the seal was completely dry, which makes me think it only leaks in the summer when the hot weather makes the fluid expand?

Either way, I sanded down the scratch, but I think I sanded it to the bare metal. Looks like the tube is chrome plated, I sanded down a spot of of the scratch to bare steel, so now it is going to rust.

Eventually I'll just have to replace the tube.

It'll only rust if you're not riding enough! Cool

The seal will keep it wiped off and leave a thin coat of oil on it, so rust shouldn't be a problem--- at least until you can locate another fork tube.

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