Help with fork rebuild

[the cueball]

Hello foccers....


So I've done my fork seals, bushes and rebuilt 1 fork with no issues...


The second one however is doing my head in... the damper bolt isn't sealing properly and is now leaking oil out.


I've got the damper rod held properly, so it's not spinning.


At first I torqued it up to the correct 30 NM spec as per the service manual.


Then I've hit it with the impact driver... both on the bench, and built up (minus the oil) on the bike.


I've taken it apart several times and made sure all the threads on the bolt and rod are clean and have no damage.


Everything I've done so far doesn't stop the oil dripping out... it's not a heavy flow, just drops every minute or so.... but obviously I don't want to rebuild the bike and use it knowing this...


Has anyone had this before?!?


Any other ideas to solve it?


cheers!!

[celticbiker]

This is always a pita.
The correct way to fix this is stripping down again clean the seating surface and use a new copper washer.
You can however re use the old one of you anneal it first (heat to cherry red and allow to cool) this will allow it to form to any imperfections in the mating surfaces.
A more Heath Robinson approach is to clean and decrease the bolt and washer and mating surface, liberally apply gasket compound and re assemble, allow to cure overnight and it should seal it up.

[celticdog]

Yep it's a bugger if you've done everything right and it's still got a bit of a leak. Check the condition of the plastic white collar and spring at the bottom of the damper rod, if it's damaged you'll need to replace it.

[the cueball]

cherrs, I'll dismantle and give everything a check over....