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nicks in forks repairable?

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ddemlong

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Aug 14, 2012
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Hey Guys, I have a few nicks in the fork tubes that are causing the seals to leak. I haven't had the bike too long and (reportedly the 3rd owner) knew the seals would need to be fixed. When I initially bought the bike I noticed the leak but not the nicks, although the bike only had 10K miles and looks as if everything was factory, I am pretty sure they are stock seals and coming up on 10 years old. I know, should have noticed them when inspecting.

Anywho, when it comes to the nicks I know people have sanded down any rough area with 6-800 grit and used epoxy, jb weld etc to fill the divot before sanding again with 1200 ish paper.

My question here is has anyone actually done this with success on our bikes?

Maybe just an R1 front swap?
 
A lot depends on how deep the nicks are.

I developed a fork leak on my RZ350 and replaced the seals on both legs, then noticed the leak was back. I looked closely and realized there were a few nicks on the leg that was causing the problem, they were hard to see, but easy to feel. Some 1000 grit paper made them disappear in short order. Bike has been leak free since.

If your nicks are deeper/larger, you may have no choice other than replace the fork tube.
 
Been sanding them out with 600 with oil. I am not too worries about causing additional scratches with that high of a grit.. They are smooth now but when I get on the forks compressing them I notice the oil still gets brought up at the nick. I know the seals are more than likely cut since they were sharp before. I attempted to fill with a clear epoxy but it wouldn't stick to the chrome. Filled then in the JB weld and will sand em when I get home. Hopefully the JB stays in there. After wards I will polish them with 1k or 1500. Heck kinda just looking to make sure I do not cut the new ones right away when I get the seals installed.

New tubes are just so expensive. I could prob find a complete R1front and install for the price of new tubes.
 
ddemlong said:
Been sanding them out with 600 with oil. I am not too worries about causing additional scratches with that high of a grit.. They are smooth now but when I get on the forks compressing them I notice the oil still gets brought up at the nick. I know the seals are more than likely cut since they were sharp before. I attempted to fill with a clear epoxy but it wouldn't stick to the chrome. Filled then in the JB weld and will sand em when I get home. Hopefully the JB stays in there. After wards I will polish them with 1k or 1500. Heck kinda just looking to make sure I do not cut the new ones right away when I get the seals installed.

New tubes are just so expensive. I could prob find a complete R1front and install for the price of new tubes.
Click to expand...

The JB Weld should do the trick. While I have no personal experience repairing forks with it I have heard of others having good success.
 
NJFZ1 said:
The JB Weld should do the trick. While I have no personal experience repairing forks with it I have heard of others having good success.
Click to expand...

I tried the JB Weld the other day after the epoxy I bought failed to stick to the chrome, and it help up well. It sanded better than the epoxy too. I went out and rode for 75 miles. Barely any oil came out. It was mainly just a bit dirty from all the junk that got caught in there through the sanding and what not.

I actually expected more oil to come out than what did after that ride. Now just to replace the seals and it should be golden. :woot:

It doesn't look bad either. You wouldn't notice unless looking for it or inspecting the bike. Since the JB Weld is sanded flush with the surface of the chrome it doesn't draw attention.
 
I know it doesn't look like much (and hard to see which is a good thing) but its smooth to the touch with no sharp edges which is what matters.

Gray spots are the JB weld filled nicks

IMG_20121015_162006.jpg
​

IMG_20121015_162107.jpg


Time to replace the seals and ride without worry. :icon_beer:
 
Little bit of an update about 150 miles since the fix and first ride and I have not seen any additional oil on the tubes (after a quick 70 mile there was a little but could have been residual). I still intend on getting the seals replaced since they are old and I am unsure how much oil has been loss. Glad to see the leaking has stopped
 
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