Adam

[Adam1977]

I have 2011 gas gas 280 with tech forks, fork seals leaking, removed forks and internals tried fitting new seals. New seals will not seat properly as I don’t seem to be able to get the bush to go back into the fork leg. Having spoke with various people and damaging 3 sets of seals on what should be a fairly straight forward job, does anyone on here have any advise/come across and similar issues ? 

[lemur]

I found that most of the replacement bushings need some careful filing to make the slot larger, which effectively makes the bushing fit the bore much better.  Make sure you put the bell shaped washer in correctly or that will rapidly destroy the new seals. Lot easier to show somebody how to service forks then to describe it.

 

[lemur]

Dry fit the new bushing onto the stanchion tube first.  The slot in the bushing when it is compressed to close should provide an interference fit on the stanchion tube and not a sloppy fit.  Now you will be able to reassemble it fairly easy.  About a foot long length of ABS plastic tube like used in a central vacuum with a saw cut down one side is a good improvised tool for bumping things back together.  

Not all aftermarket fork seals are created equal, some are actually intended for rotating shafts instead of stanchion tubes which are closer to hydraulic rams.  That's the difference between a 4$ seal and a 20$ SKF seal.

The bell washer will always have the biggest hole towards the oil seal, that way the washer bangs up against the steel part of the oil seal and not the delicate rubber lip part of the seal.

[Tr1AL]

@Adam1977 Go to www.thehellteam.com look in suspension in the Tech support GASGAS INFO page then go to  - TECH forks then  MANUAL-OIL-SEAL-CHANGE Trial SX and DX.

Edited July 29 by Tr1AL