new fork seals leaking - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 2 Old 04-26-2013, 10:08 PM Thread Starter
1st Gear
Join Date: Mar 2009
Location: Fernie, BC
Posts: 71
Thumbs down new fork seals leaking

Ok, I just did an easy 60 minute ride on my new fork seals...amoung other things. I noticed after that there was some oil leaking out from under my new shock boots. Obviously it is coming from the fork...same pale green as the fork oil.

I replaced the originals with moose racing seals. The originals had an obvious upper and lower edge. The top edge of the seal was flat and the lower edge had a 'groove' in it which contained a small spring that went 360 degrees around the fork.
The new Moose seals did not have a flat side. Each side had a 'groove' with a spring in it. The new seals had a very slight taper to them on the side. I put them in with the smaller diameter at the bottom side and the larger diameter at the top. In hindsight I think this was a mistake and thus the problem I have now.

If I had put the wider diameter in on the bottom, the pressure at fork compression would press the seal tighter against the inside of the fork tube.

Can anyone confirm that this is my problem with my leaking new seals?

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post #2 of 2 Old 04-27-2013, 09:26 AM
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Join Date: Dec 2011
Location: Eugene, Or
Posts: 40
You got it exactly right.
I did this exact same thing with my new seals, also moose. I put the taper side in first and they leaked right away. I just carefully removed them and flipped them over and no more leaks. From my research (after the fact) this seems to be common with this brand of seal.
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