WTB: Inner fork tube for 89-02

[bombsquad83]

I measured properly with the tube completely compressed with no spring as the manual states.  There was 99mm to the fluid from the top of the tube.  I don't think the alignment is off...the axle had no issues getting through both forks and the wheel.  I'll just replace the seal and see what happens.  I anticipate that it will not be a problem after that.

[BockinBboy]

Probably just the old fork had rust/pitting in just the right spot to ruin seals... Then using the gently used seal (and unknowingly damaged)from the old tube on the new tube managed another leak. 
At least I hope it turns out that simple for you.

- Bboy

[bombsquad83]

I didn't use the old seal.  The fork I got from Adidasguy was fully assembled minus spring, cap, and oil.  I installed it with the seal that was in it.  Also the tube that he sold me looks really good in the area where the seal touches.  Very few imperfections.  It probably just needs a new seal.

[BockinBboy]

Oh I see.  Just bad skimming on my part.  Definitely hope it gets sorted.  Seems like this just keeps coming back to hang over head.  (Restraining myself from forking jokes right now...)

- Bboy

[bombsquad83]

Get the fork out!

[bombsquad83]

Alright, update on this.  I went to replace the fork seal tonight.  Problem was whoever put the damper bolt in last must have used an impact wrench and torqued the crap out of it.  I did everything I could to get the bolt out, but it was already a little rounded and it kept getting worse.  I ended up having to drill the bolt out.  There was minimal damage to the lower tube, but I swapped it out for my old lower tube and used the nice upper tube that I bought from adidasguy.

I also realized that I had overfilled my tubes before.  I was filling to 99mm, but since I have progressive springs that take up more space, I should have been filling to 130mm.  I did that this time and switched to 15w fork oil as well.  I also polished the fork tubes a bit with some 000 steel wool.   I'm pretty confident that everything should be good for a while!

[adidasguy]

So, is the fork I sent you OK? Or is that the old fork you took apart? I am confused......

[bombsquad83]

The one you sent had the damper bolt completely stuck and needed the seal replaced.  I had to drill out the damper bolt and use my old lower tube because of minor damage from the drilling.  I used the upper tube that you sent me in my old lower tube with a new oil and dust seal.

[adidasguy]

Hmmm.... I had thought the seal was good. It wasn't leaking before I drained it to ship it.
I did know the tube was near perfect.

Maybe the overfilling of oil kept blowing the seals?

Well, now I have an impact wrench and have been rebuilding all my fork sets. Glad the "Disposable Tool Store" (harbor Freight) opened up near me. I found an impact wrench is the only thing that can get those things opened up. I fought them so I went down the road and bought one (and lots of other tools - I like buying tools!)

Good you've got it all working now.

[bombsquad83]

The seal was definitely leaking as soon as I put it in.  The other fork has been overfilled for 1600 miles with no leak.  It's all taken care of now though.