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Leaky 400 fork (R)

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Went to ride my 400 around today....

noticed what I thought was brake fluid on my right fork... turns out it is fluid from my right fork.

It's noticeably leaking but no puddle on the ground yet.

I've never messed with forks, ever.

I checked my Service Manual to go over the procedures to change out the seal.

I think I could handle it except the step on page 13-10 that indicated I need a special Honda tool.. DO I NEED that tool? what can I use instead? (do I even need to do this step to change out the dust seal?)

anything else I should check? or just swap out the dust seal and refill?

2012-01-04184353.jpg?t=1325724777

2012-01-04183833.jpg?t=1325724789

this might be why it's leaking.... do I need a new slider? will changing the seal for now be good enough for a while? (1 year ish). I don't have much money to put into it right now... just want a temporary fix, unless I'm wasting my time. The damage is about 6 inches from the seal, meaning it's doesn't get touched by the seal much (I think).

2012-01-04183901.jpg?t=1325724783

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sand that baby down. keep going up in number until you get it perfectly smooth

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I make my own [ Special ] tools and that was an easy one to make.

I used a pc. of 1'' gas pipe. All you need is a welder. Good luck.

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lots of guys just use an impact gun to remove the bottom bolt first while the spring

is still installed holding the top from spinning

---------------------------------------------------------------

but if you make a tool - forget the plastic pipe !

I made one out of aluminum conduit and it worked good for putting it back together

BUT when I used it the next time to remove the bolt it broke off the little fingers

it would have been fine for reassembly - should have used the impact wrench to remove

---------------------------------------------------------------------------------------

made a new tool out of a piece of black iron pipe this time !

just hacksaw down the spots where you need the fingers and then

remove the rest with a grinder or a few more cuts with the hacksaw and

then break away with a pair of visegrips

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the problem with tightening it up with the impact wrench is that it is an aluminum bolt

and I wanted it tight - but not stripped the threads

some maybe happy just putting the impact on the lowest setting

-----Remember that if this bolt comes out the fork will come apart------

this would be bad when you are 5' in the air over a jump !!!

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I've rubbed out tiny scratches in fork tubes but that is a good gouge. If you sand it out, you may (by looking at the pic) take too much off the material of the fork and end up with a flat spot, where the oil will still leak out of there or simply too much is taken off the outer diameter of the fork tube and the seal won't be tight enough and it'll still leak. DIY fork rebuild is cheap enough to try it and if it still leaks, then you need a fork tube - ouch!

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I think I'd fill in those deep gouges with JB Weld, use some fine sandpaper to shape it and feather it into the tubes diameter. That before replacing the tube.

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That fork has no hope of sealing until that crevice is made smooth somehow. Either filled in or sanded, the seal doesn't know. It has to be flat and smooth.

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