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No questions, just an experience.
My front forks were working OK, but had a bit of a leak out the top. So I picked up a new seal and dust jacket from my Honda dealer and with the aide of my neighbour set about fixing the problem in one night.
What I discovered was, the left and right inner springs were significantly different. One was about 70mm shorter and about 5mm narrower. To accomodate this they had added a spacer, to make up the difference, which apepars to be a piece of galvinsed steel pipe cut with a hacksaw. Im sure this is not standard.
Also found a couple of circlips with only one head (the others had been snapped off under previous repairs) and they are really hard to remove. Finally, the pipe guides were split from top to bottom. I do not even know how this could happen.
This was my first time at removing the front forks, I would advise that it is relatively straigh forward as long as you have a set of Circlip pliers and a manual. And a bowl of petrol to clean the parts. And a good memory of where all the bits were at the start becuase the manual is not very precise on where all the bits go.
I initially put the fork seals on upside down (there is no clear indication of top and bottow and the manual did not help), and they fitted perfectly. This should have been a clear sign that something was wrong. Then got everyting back together and it leaked worse than when I started.
I stripped it again and turned the seal up the other way and with about 15 minutes of forcing them against their will into place using a small hammer and the extension socket for a 1/4 socket drive I managed to wedge them in tight enough that I could put the circlip back on the top.
So my fianl tip is that if you put on a new set of fork seals and they fit perfectly, then you have done it wrong. Turn them over and force them into place.
Cheers
Tim
P.S. I have temporarily returned the non-matching springs back into the front forks, until I can source a new set, and can justify another ngiht of my time to strip the front end.
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