R80 G/S fork leak

Pedro's Jupiter · 01-13-2013, 09:20 AM

So, I decided to rebuild my R80 G/S forks and completely disassembled them; this included removing the large plug at the bottom of each fork that the large hex nut that secures the damper rod and small drain screw insert into. Now I wish I left that plug alone!

The problem encountered is that the O ring that seals the plug by fitting up inside the fork tube needed replacement but does not appear on BMW parts microfiche diagrams and I am told by a respected BMW parts supplier is not available. The correct size O ring isn't available locally & using Napa "sleeve retainer" as a sealant resulted in significant fork oil leaks.

I would appreciate advice on either the BMW part number for this O ring or a source for such O ring or other ideas on how to seal this plug.

Many thanks!

veesquared · 01-13-2013, 09:50 AM

Try this first . Buy a sealing washer . On the outside bolt place this washer. Torque to spec . Maxbmw has a online parts search as does BikeBandit.com Normally BmW will provide the dimension of the Oring . You can then source the appropriate size.

Airhead Wrangler · 01-13-2013, 10:07 AM

They're either fiddy or fiddy-five cents each depending on which ones you're talking about and yes, they are still sold. Probably much cheaper at napa though.

10

07 11 9 963 010

GASKET RING - A5X7,5

2

$0.50

11

12 31 2 322 411

FILLISTER-HEAD SCREW - M5X8

0.01

2

$0.50

12

07 11 9 963 151

GASKET RING - A12X17-CU

2

$0.55

Pedro's Jupiter · 01-13-2013, 10:31 AM

thanks for the fast responses!
The O rings shown in the above response are indeed for hex bolts # 13 and #14, however these two bolts screw into a large diameter plug (about 1.5") that fits into the bottom of the fork shaft. This large plug is the one I removed and needs sealing and is not shown in the parts diagram, nor is the rubber O ring of about 1.5" diameter that seals the plug. The rubber O ring sits against a slight shelf / groove about 1 1/4 inch up inside the shaft. Once I take it apart again I will post a photo of the plug.

Pedro's Jupiter · 01-13-2013, 11:31 AM

Well, I have now have photos and am embarrassed to say that my search for instructions on how to post them isn't successful. Where would I find photo posting instructions?

One Less Harley · 01-13-2013, 12:13 PM

I had trouble finding the large o-ring too, never did find the P/N. Ended up going to a hydraulic rubber a gasket place to get the closest o-ring available. Of course it was a little bigger in thickness than stock. I had to use a hydraulic press on the plug to compress the o-ring enough to get the circlip in place. it is awkward but can be done. Make sure the circlip is fully seated in the grove.

disston · 01-13-2013, 01:15 PM

For directions on how to post a picture; Go to the section titled "Fluff"

In Fluff find "Ask Baldy, blame AceRph"

Look for thread titled, "How to post an Image"

Here's a link but you will next time be able to find it, right?

http://advrider.com/forums/showthread.php?t=919

You do need to have a photo Account somewhere else, other than AdvRider, to host pics you post. If you still have trouble ask again or you can write me.

Pedro's Jupiter · 01-13-2013, 02:26 PM

Thanks for the link to photo instructions; in the meantime I located the proper sized O ring on the Mcmaster.com web site. For anyone who also seeks this o-ring here are the specs:
width - 1.5 mm
i.d. - 39 mm
o.d. - 41.5 mm
Mcmaster part number 9262k661 for a package of 100. If someone needs some of these, contact me as I will soon have 98 of 'em unused.

Alternatively Napa "right stuff" gasket maker was suggested, but would likely be messy and imprecise.

01-13-2013, 09:50 AM	#2
veesquared Adventurer Joined: Feb 2004 Location: Center of the Smokies Oddometer: 18	Oring replacement Try this first . Buy a sealing washer . On the outside bolt place this washer. Torque to spec . Maxbmw has a online parts search as does BikeBandit.com Normally BmW will provide the dimension of the Oring . You can then source the appropriate size. __________________ Always keep people in your life that charge your battery. Not those that drain it.

01-13-2013, 12:13 PM	#6
One Less Harley OH.THAT'S GONNA HURT Joined: Nov 2006 Location: Bowling Green, Ky Oddometer: 3,814	I had trouble finding the large o-ring too, never did find the P/N. Ended up going to a hydraulic rubber a gasket place to get the closest o-ring available. Of course it was a little bigger in thickness than stock. I had to use a hydraulic press on the plug to compress the o-ring enough to get the circlip in place. it is awkward but can be done. Make sure the circlip is fully seated in the grove. __________________ 2004 BMW R1150RS 1984 BMW R80G/S (wrenching index) 2003 Suzuki DRZ 400S (TAT Prep) One More DRZ does the TAT (Ride Report) One Less Harley screwed with this post 01-13-2013 at 01:20 PM

01-13-2013, 01:15 PM	#7
disston ShadeTreeExpert Joined: Mar 2011 Location: Silver Spring, Md Oddometer: 4,998	For directions on how to post a picture; Go to the section titled "Fluff" In Fluff find "Ask Baldy, blame AceRph" Look for thread titled, "How to post an Image" Here's a link but you will next time be able to find it, right? http://advrider.com/forums/showthread.php?t=919 You do need to have a photo Account somewhere else, other than AdvRider, to host pics you post. If you still have trouble ask again or you can write me. __________________ Never memorize something you can look up. ---Albert Einstein

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01-13-2013, 09:20 AM	#1
Pedro's Jupiter ^OP Adventurer Joined: Apr 2004 Location: Colorado Oddometer: 47	R80 G/S fork leak So, I decided to rebuild my R80 G/S forks and completely disassembled them; this included removing the large plug at the bottom of each fork that the large hex nut that secures the damper rod and small drain screw insert into. Now I wish I left that plug alone! The problem encountered is that the O ring that seals the plug by fitting up inside the fork tube needed replacement but does not appear on BMW parts microfiche diagrams and I am told by a respected BMW parts supplier is not available. The correct size O ring isn't available locally & using Napa "sleeve retainer" as a sealant resulted in significant fork oil leaks. I would appreciate advice on either the BMW part number for this O ring or a source for such O ring or other ideas on how to seal this plug. Many thanks!

01-13-2013, 10:31 AM	#4
Pedro's Jupiter ^OP Adventurer Joined: Apr 2004 Location: Colorado Oddometer: 47	thanks for the fast responses! The O rings shown in the above response are indeed for hex bolts # 13 and #14, however these two bolts screw into a large diameter plug (about 1.5") that fits into the bottom of the fork shaft. This large plug is the one I removed and needs sealing and is not shown in the parts diagram, nor is the rubber O ring of about 1.5" diameter that seals the plug. The rubber O ring sits against a slight shelf / groove about 1 1/4 inch up inside the shaft. Once I take it apart again I will post a photo of the plug.

01-13-2013, 11:31 AM	#5
Pedro's Jupiter ^OP Adventurer Joined: Apr 2004 Location: Colorado Oddometer: 47	Well, I have now have photos and am embarrassed to say that my search for instructions on how to post them isn't successful. Where would I find photo posting instructions?

01-13-2013, 02:26 PM	#8
Pedro's Jupiter ^OP Adventurer Joined: Apr 2004 Location: Colorado Oddometer: 47	Thanks for the link to photo instructions; in the meantime I located the proper sized O ring on the Mcmaster.com web site. For anyone who also seeks this o-ring here are the specs: width - 1.5 mm i.d. - 39 mm o.d. - 41.5 mm Mcmaster part number 9262k661 for a package of 100. If someone needs some of these, contact me as I will soon have 98 of 'em unused. Alternatively Napa "right stuff" gasket maker was suggested, but would likely be messy and imprecise.