Well, the job is done. Being alone to do most of it, it took longer than if I would have had someone who had done it before or could have read the manual while I did the work.
I decided from the get go that I would replace all parts even before I did the disassembly so I ordered those a few days before project start.
My progress is as follows:
read and re-read Clymer Manual (more on that later). 1 hour or so
Disassembly as per manual, cleaning, checking out other parts that are disassembled in the process but not necessarily part of the forks. 2 hours
Put parts in forks, installed 20 weight oil,called wife to garage to help with springs (no she is not stronger than me, I needed someone to turn socket while I put the pressure down on them)
. 2 hours
Intalled forks on bike and went for test ride but rain started hard after less than 1 click. Noticed a leak almost immediately on both sides. I was very pissed and wondering what step I had missed as I was sure I had followed all the steps. Came back home and re-read the manual. I was sure I had not missed a step. 1 hour
Go to forums and google and search for possible cause of leak. Find a reference somewhere "Do not install seal as per Clymer manual because the way the manual says is backwards"
Well, let's just say my thoughts and words were not appropriate for a Sunday Morning. I was less than pleased. I was hoping that the seals were not ruined. Seeing as wife had plans for me the rest of the day Sunday, solving would have to wait.
I put on the coveralls and got to it. Dissassembly this time was much quicker as I decided to take the short cut and just take the forks off without taking off seat, tank cover, etc. I actually drained the forks while they were still on the bike and removed one at a time to work on it.As I had somemore fork oil, I decided against using the oil that I justdrained even though it had no miles on it. Disassembly of the fork parts was a breeze but I had a hard time to put in the seal in the first fork as I was trying not to damage it.
The second side was almost too easy and was actually concerned that that seal was "toast". Called the wife to help me out again and got everything back together. To continue with the bad luck, as I was tightening the last wheel stud, it broke. That was all I could do that night.1.5 hours
I picked up a stud at the local dealer, I wanted 4 but at least they had one (other 3 coming). I replaced the broken stud, double checked my reinstall and went for a drive. 15 miles and no leaking.15 min plus drive
So what should have been a 2-3 hour job turned into much longer. But in all the frustrations, I am glad I did it myself.
I want to thank all the people who posts their experiences and expert advice.