How to
I have never seen seals replaced without dismantling the forks. The seal will come in a fork revbuild kit whether the bushings etc are used or not. Obtained separately but necessary in any case are new lower fork bolts and copper washers. I suppose it might be possible to get the seal out of the fork leg without completely dismantling the fork but the normal way of removing the seal is to use the slider as a slider hammer tool to drive the upper bushing and seal from the fork leg which requires removal of the lower bolt and washer and pretty much fully dismantling the fork. You will also need a special fork holder tool or at the least a pair of vise soft jaws and it is critical how much fork oil is added back into the fork as too much will make the ride unacceptably hard and too little will allow the fork to compress too much and be too soft. You also really need an appropriate seal installer to reinstall the seal and upper bushing etc. All that being said:
SOURCE: 07 harley street bob. front fork seal leaking
Not very common, but I don't see how the seal could scratch the tube. There are a few millimeters of clearance between the tube and metal part of the seal. The rubber seal rubs the tube and is bonded to the metal ring. Either the tube was scratched during assembly or the seal was BADLY dented somehow. Further, the tube is hard chromed and the seal metal is soft steel. Go figure!
FLST, FLSTC, FLSTN 13.4 OZ 395CC 4.41 Inches 112.0mm
FLSTF 13.4 OZ 397CC 5.04 inches 128.0 mm
FXST, FXSTB, FXSTC 12.5 OZ 370 CC 6.69 inches 170.0 mm
FXCW/C 24.5 OZ 725CC 4.80 inches 122.0 mm
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