2nd question first, yes fork oil can leak out from the around the bottom bolts. At the bottom of the fork is an allen bolt, 6mm. The manual recommends using a locking agent on it, most here don't recommend it. When I did my seals last year I reinstalled without agent, and one was fine, the other did a very slow drip. I'd get two or three spots worth overnight. I redid them again last weekend (one had no leak on the bottom but the seal didn't seat first time, the other seal was fine but was leaking at the bolt), and when I reinstalled I used some anerobic gasket sealant on the threads of the bolt in lieu of a locktite. A week on and 500km later, no leak, and it shouldn't be too difficult to break free for the next time.
I'd say about 2-3 hours for the change. On mine, the most time was spent on disassembly, not actually changing the seal. You don't have to remove fairings et al to get to your triple so it should be pretty simple. Rob Davis' page is excellent for instructions. Be prepared for difficulty in removing the allen bolts. An impact driver may be required. Nothing worse than having it all torn apart and realizing you don't have the right tool to finish the job.
Centre stand, jack under the engine to get the front wheel off the ground. I use a short length of 2x8 lumber between the jack and the engine to evenly distribute the weight. Remove your brake caliper, and bungee it back so it doesn't hang free. Remove the speedo cable. Take off those 1/2 moon thingies. Mine were marked with punch dots to show which was which, right fork 2 dots, left 1, with dots on both the fork and bracket. Your wheel should drop out. My GL I had to deflate my tire to clear the fender.
Remove fender.
Remove air balancer crossover hose if you have the air suspension (it's at the top of the forks)
Loosen the spring cap at the top of the fork. Don't remove it, just break it free. The triple will act as a vise to help with this, you want to try to avoid using a vise on the fork tubes when off the bike. (or be carefull, use soft jaws)
Loosen the upper and lower pinch bolts on the triple tree on each side. You may want to note your fork position in the triple, so when you put 'er back together you have the same ride height if desired.
The forks should drop out the bottom of the tree.
Remove the fork cap, carefully as it is spring loaded and under pressure. You don't want it hitting you in the eye or have pieces inside fly to the mystery places where they will never be found. I think it is the same place odd socks go from the dryer. Press down as you loosen!
After the cap is off, you will find a short spring, a spacer (washer type thing), and a long spring. Note the orientation of the spring coils they will be tighter on one end, for later reinstalation. Remove these. They will have gross grey oil on them with a pudding consistency likely! Wipe them clean. Pump the fork a few times to get as much gunk out as you can. I left mine inverted for 1/2 hour to drip out.
So far so good.
Remove the allen bolt at the bottom. Don't strip it! Use the right tool.
If you are holding the fork upside down, when the bolt comes out a piston with the rebound spring will fall out. Note the orientation for reinstallation.
Remove the dust cap, carefully prise up with a flat screw driver.
There you will find the dreaded circlip/snap ring. This to me was the biggest PITA. Again having the right tool makes this short work.
With the circlip out, IIRC there is another bushing to remove. grab the slider with one hand, the fork lower in the other, compress then rapidly extend them. This will pop your old seal out, and the slider will come free for cleaning. Note the condition of the fork slider bushing, it's a 2" collar at the end. If it's excessively worn it should also be replaced (copper surface showing over 3/4 of it, it normally has a teflon type surface).
With everything clean, it's time to put back together. Position the new seal, with the numbers facing up, centre it in place. Guys here bought a 1 1/2 inch pvc pipe fitting to place over the seal to tap on to drive the seal. I bought one and didn't fit, so I positioned my old seal on top of the bushing on top of the new and used that to drive it down. Worked great. You have to get it down far enough so the grove the circlip fits in is exposed.
Circlip in, seated in it's groove and your ready to reassemble! Dust cap on, Piston with rebound spring in, put some sealant on the allen bolt and reinstall and tighten. It won't thread in unless you have the fork in an extended position.
Drop in the large spring, spacer and top spring. accurately measure the correct amount of fork oil for your model (listed on Rob's page). You need the same amount for both forks. If you spill some out you'll have to empty and start again to ensure they are balanced.
Extend the fork, take the top cap, I use a rag between it and my hand, and compress the springs down to tighten the cap in. I put the fork lower between my feet, hold up the slider with my left hand and push down, turn in with my right. Left hand keeps the fork extended so you don't have to compress the springs far to install the cap, much easier!
Your fork is now together, repeat and rinse with the other, and put 'em back on the bike!
Don't do them both simultaneously, so you have a complete one as a referrence if you forget where all the bits went.
I am not a great mechanic, with you dad helping you it should be a piece of cake. If I can do it anyone can (of course I had to do it twice....
Rob Davis' link:
http://www.elsham.pwp.blueyonder.co.uk/cx500/front_forks_seals/
It's not that hard, again if I can do it, you can, especially with your mechanic dad on hand. It's a few steps, but they are all simple. Just have a plan for that allen bolt if stuck and get a proper snapring tool. I bought a cheapie and it didn't work well, ended up using one prong of it and a small flat screwdriver. Otherwise, it's like lego, take it apart, put it back to gether.
If your stuck, you know where we are!
Darren
edit: You wont believe the difference in the ride when you are done. It will be worth it, trust me.
Exothermia wrote:I could see that oil had been leaking profusely from the two bolts that the front axle holder bolts onto, on the bottom of the forks
LRCXed wrote:put a closed end wrench on the short side and tighten the bolts. THEY MIGHT JUST BE LOOSE.
WayneDW wrote:Also ran short of fork oil.