Never known a bike with so many unusual ‘issues’. Here’s the latest:
Front forks: New bushes, oil seals and stainless seal holders. Stanchions are in good order. The holes for the axle clamp haven’t been drilled into the leg. The bottom weld and mudguard bracket lug weld are fine. But the N/S leg leaks oil.
Removed the leg and stripped it again. All OK. Even filed away the counterbore around the drain plug to ensure it was flat for the copper washer. Re-assembled with thread seal on the drain plug and ptfe tape on the thread for the seal holder. Correct amount (210cc) of oil.
The leak seems to be coming from the top of the leg, but why? Oil is not under pressure there and it’s a new seal. Only thing I haven’t checked is whether the recess in the seal holder is shallow enough to ensure the seal is clamped. However, when tightening it, it doesn’t seem to be getting thread-bound (it comes to an abrupt halt) so I presume it is clamping as required. Any ideas? Never had one of these legs leak before (currently have four bikes so fitted). If it wasn't for the fact the oil gets on the tyre, I'd leave it until it runs out.