Temporary fork seal fix 2007 gl1800 airbag model

[extremetouring]

Looking for a little help. I’m traveling through Mexico nearing the city of Merida (near Cancun) and the left fork seal clip has partly snapped out of the seat (about 3/4”). As a result the dust has popped out and I’ve lost a fair bit of fluid. The Honda shop in Merida does not have the seals in stock and require 10-15 days for them to come in. I don’t have the luxury of extending my vacation 2 weeks. For now I’ve cleaned up all the oil and tied a couple of rags around the seal but would like a better temporary fix until I return to Phoenix in 2 weeks.

Is there a way to drive the clip back in without special tools? And if so can oil be topped up without removing a lot of parts? I will be doing the repair in the hotel parking lot and have a limited number of tools.

Left fork seal clip

Another angle

[MikeB]

Has the seal failed or did just the clip come out of the journal and then the seal moved enough to allow the fluid to leak out? Can't say that I have ever seen this happen.

As to getting it back together, I'd have the Honda Dealer attempt to drive the seal back into place and re-seat the clip. The Honda shop should have a seal driver.

[extremetouring]

The seal pushed up and popped the clip out and the dust cap came out as well. The highways are paved but unfortunately there are tons of potholes and sections where repairs are started but not completed. And then there are the endless speed bumps in and out of every village. It tough to say which one cause the seal to fail. Our speed was mostly around 110 kph (65 mph) so the oil sprayed back to the engine and fortunately very little got on the brakes. Based on the mess I had to clean off I would guess I’ve lost half of the fluid in the left fork.

I think I may have to do like you mentioned and see if the Honda shop can at least get the seal down and clip back in place.

[MikeB]

It would be highly unlikely that the clip would pop out of place if it had been properly installed. If the seal is not damaged, which is a good possibility, reseating the seal, clip and dust boot should prove easy enough for the Honda mechanic.

[WingAdmin]

If you can get the seal pushed back down, even a flat blade screwdriver (or two) can be used to get that clip back into the groove. Then you can push the dust cover back into place. Make sure it's on the center stand to get as much pressure off as you can when you do this.

That must have been a hell of a pothole!

[GoldWingrGreg]

If you lay the clip on a flat surface, it needs to lay flat. With a couple of pair of pliers, you can probably make it that way. Once installed, it need to snap into it's grove. As others are saying, you might be able to drive the seal back into place with a punch and a hammer. Be carefull not to scratch the fork tube, any scratching will damage and cause your seal to leak. As for filling, if you have OEM fork caps, loosen the top cinch bolt (12mm), and remove the fork cap (17mm). To properly measure the fork level, the spring needs removed (coat hanger with a hooked end), and the fork fully collased. That means that the front tire, fenders, and caliper and secondary m/c removed from the fork. Add fluid until the level is 5" from the top of the foirk pipe. To get to the fork cap, without removing the meter panel to remove the black plastic fork cover, turn the bars for access, and with a razor, cut the fork cover. I'm sure new fork covers are still available, and cheap. OEM fork springs require 10w fork oil.

Here in the states, most dealers will not have a seal kit, bushings, or clip to repair your fork, so it's probably not even worth the time looking down there. Most any m/c shop should have fork oil.

Good luck.

[extremetouring]

I brought the bike into Peninsula Garage in Merida, MX to see what they could do to help out. This is a full service shop that carry Triumph and a Chinese brand CF Moto. They’re a young group of guys that are very professional and passionate about motorcycles. They disassembled the left fork and have installed a fork seal for a Triumph Tiger which seems to fit fine. The dust cap on the other hand is a bit taller but I’m fine with that. As long as it holds until I return to Phoenix that’s all that matters. If it doesn’t I’ll post again for the Hell of it. Thanks for everyone’s input.

[GoldWingrGreg]

Glad that your up and running.

Just an FYI ... I had a customer who shipped his Wing and toured South America. He too talked about poor pavement conditions. Anyway, when he shipped his Wing back and sold it, eventually the new owner contacted me and told me about the sub-frame that supports the trunk and saddlebags was cracked. I'd never heard of such happening, and wish I could tell you were his was cracked. But if your trunk is ever off, or things get really rattly back there, or the next time your Wing is on a lift and you can look in where the rear tire rides, you might want to shine a flashlight around and see if anything needs attention.

[extremetouring]

Great idea I’ll take a cursory look for cracks in the morning. Thanks for the heads up!

[extremetouring]

Well my luck ran out in Guatemala. Right after crossing the border from Belize the road conditions deteriorated substantially for about 50 km with broken pavement, more potholes and of course more unmarked speed bumps. The replacement seal from Triumph Tiger has now started leaking. Unfortunately, due to Easter the dealers in Guatemala City were closed this weekend so I’ve wrapped it up very well with rags and am headed back into Mexico tomorrow. An acquaintance on mine has sourced OEM seals and has them in Playa Del Carmen. Now we are just sorting out where on the west coast he can send them to. BTW, if you have wondered about making this ride I highly recommend it. There are some very technical roads with one switchback after another and streets in the small villages so steep and rough with cobble stone that you feel you should trade the wing in for a dirt bike. But if you can get past that the rewards are great!

[Scoty79]

I’m in San Miguel de Allende, MX, about 190 miles NW of Mexico City and have a set of fork seals for an 08 I can part with. I also have tools. You can message or call me at +1 757-467-2060.

Scotty

[Terry D]

I have always used a pvc pipe to fit the fork tube to get the bushings and seals in place. I doubt the seal is bad if you can remove the fork and get something like a pvc pipe to do the job without scratching the fork.

[MikeB]

I have always used a pvc pipe to fit the fork tube to get the bushings and seals in place. I doubt the seal is bad if you can remove the fork and get something like a pvc pipe to do the job without scratching the fork.

If a proper seal driver was available, removing the fork would not be necessary to drive the seal back into place.

But then again, if it is leaking again, it will have to be removed to replace the seal with known good seal.

[extremetouring]

Thanks Mike and Terry. Scotty in San Miguel, Mexico and I have connected and he has a set of seals. The replacement seal we used from the Triumph is holding in place but leaking slightly against the fork tube. It looks fine so I can only assume that the fit is just the tiniest amount off. I will monitor it over the next day and if necessary change my route to pass by Scotty’s place.