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Hi all, first post and couldn't find an existing post. I ride a 2014 500F black, with 103000 miles on the clock. I try to do all the work on my bikes that I can. Found my forks leaking so did an overhaul of both with new bushes, seals and oil and still leaking. Will replace seals again but has anyone had difficulty or ideas?
 

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Agree w/extex, any nicks or small dents in the sliding part of the fork?


Hence why I take my forks/shock off the bike and to a suspension shop for maintenance. Normally 150 bucks for servicing forks plus parts.
 

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Fork oil should be 15~20cm from top (no spring). Although, Honda factory filled 12cm from top (no spring) which is exactly 0.5L. Too much beyond that may force it out elsewhere ...
Side topic: you can also change to 2016 internals (damper & spring); while you're at it. They are surprisingly cheap.
 

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In this YouTube video on changing fork seals look at time= 18:30


the person mentions that nicks or corrosion pits on the outside of the fork tube might damage a new oil seal as you slide it on.


suggests slipping a piece of very thin plastic under the seal before sliding it down the fork tube, lubing with the grease that comes with the seals.
 

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103,000 miles until a seal leak - wow! My left fork seal started leaking at ~25,000 miles. Anyways, I replaced my fork seals with an SKF kit and here's my experience. I found a small scratch on the fork but very minor. I went ahead with the seal replacement. The new seal leaked as well (although a lot less and only a slight film on the fork) for around 1,000 miles. I kept wiping it down every so often to make sure that bugs or dirt doesn't get in. Surely enough the leak started to disappear and then the leak completely went away. I read on a Suzuki form that there is a "break-in" period and this turned out to be true in my case. I have since put another 1,000 miles and it looks good.

Hope this helps
 
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