Bonneville America Forums Forums Technical Forums General Tech Fork pinched at seal

Pictured is some damage I took back in August. Shroud dented in and pushed the metal into an uneven surface, warping my dust seal. My issue now is how to get the dust seal onto a surface that isn't flush. I'm putting gaiters over top of them. I could really use some advice. Not sure how to proceed.

I'm thinking you're going to have to file or grind it down so it's flat and the seal can sit flush again

I guess the fork is gonna have to come apart for this huh. Was hoping to avoid that but What the hell. Maybe I could take it to the Local Triumph shop, I hear the guys in Long Beach are fantastic.

crap. I need a new outer tube. Sucks because right now this thing is good, doesn't leak, but the crack there will be a problem once it's opened or even before that.
The job scares me but I don't wanna give the mechanic $125 to do it for me. I've seen some decent vids on youtube but none that do a whole breakdown and rebuild of the shock. Do any of you guys know a good resource? I have the shop manual I've been searching for, I know I need a few odd tools to do it. I should use my garage to it's fullest!

Disassemble the fork leg.

Remove any rubber seal parts.

Get a socket or any round piece of metal/steel that will just fit inside the damaged bore put it vertically in a vise. Heat the outer edge with a propane torch or oxy/acetylene. Don't melt the metal just soften it so it can be worked back out to its right size. Work the aluminum out till you get a round bore and use a bigger socket each time you work it to a larger i.d. Use a mallet to tap on the leg when the leg is over the socket, you don't want to damage the outside of the slider.

As long as the oil seal bore is round and isn't leaking you should be able to fit a new dust seal and it should work.

If the piece cracks and breaks off you could put a new dust seal in place then use JB weld or a similar product to rebuild the broken lip. There is at least 3/4 of a good bore that will position the seal and allow you to rebuild the lip.

Seeing as you are putting gaiters on you don't need dust seals anyway, thats what gaiters are for. What part of SO.Cal are you? I live in Fallbrook which is 50 miles north of San Diego and could help you do it if you wanted to.I've got all the eqpt needed to do this Des.

Dude, I don't even know what to say. That's really nice of you to offer. I live in Long Beach. I'd bring a 6 of beer your choice if you want. I suppose I should take the $ saved and get new springs? It's 14 years old.

Keep us posted on how this works out. I have an 03 Speedmaster that I am going to be disassembling for parts. I am not quite ready to tear it down yet, but when I do I may have a fork leg available.

tikiman. i'm about 90 miles south of you, send me a pm and we can work this out for you, Des.

I might have a lower leg too I need to disassemble them but you can have one if needed just wont soon

Hi guys, I really appreciate the parts offer. Looks like I'll be in the market for an outer tube. If any of you are looking for cash or a trade, let me know, I'm a good customer!