This issue I found to be a break in the wire that you ground from the cdi when derestricting the bike. went completely back to normal once I reterminated the connection.
sorry for the late update on this, better late than never though haha could help someone in the future with a similar issue
@SpookDog said in Fork seal replacement:
If you’re replacing the seals you may as well replace the bushes at the same time (Brooks suspension sells top & bottom bushes)…
You can use an old broom handle to tap into the 27mm female fitting inside the fork and turn/hold it with pipe grips…
Any seize/sticking is usually the 10mm Allen bolt head being corroded to the ally fork bottom (not the threads) White crusty crap builds up between the two different metals. I use silicon sealant to fill & seal the gap between the two, or at least cover and waterproof the bottom of the forks…I’ve had to drill out the Allen bolts from both sets of forks I’ve worked on. I drilled them out to 10.5 - 11mm then hammered the Allen key into them and got good purchase. Loads of heat was needed! Even after I’d undone and removed the inner (with a 27mm tool-bit I bought for £22) and it was just the bolt head stuck in the fork bottom!!…
Oh god i hope i dont have the same issue with that allen bolt at the bottom of the fork but i do have a feeling i will as i had a go a while a ago and cracking one free and it didnt budge just thought i was going to round it off so i stopped. I have bought the 27mm for the inside and i do have an impact gun now which may help free up that bolt at the bottom. I will definitely apply a load of heat like you mentioned and ive soaked it in a tonne of penetrative fluid also. Aim is to give it a go tomorrow so wish me luck haha. I was hoping that the bushes will be ok to be reused as there's no play that i can feel in it. Just oil and dust seals and some fresh oil and i do have a tub of copper crush washers that im sure will have the right size in for the bottom of the fork. Worst case i will have to drill the allen keys out, any ideas where i could pick up a couple new ones of them from if so?
@HOTSHOT-III Absolute perfect response mate was just what i was hoping for haha thanks mate. I dont have a spare spindle unfortunately but i could definitely knock something up to do the job perfectly just needed those sizes you've provided. Cheers for that 
@HOTSHOT-III said in Fork seal replacement:
If the forks are the same as the early bikes you need a 10mm allen key/hex bit for the allen bolt at the bottom of the slider, and a 27mm hex bit to hold the damper rod which will allow you to undo the bolt:
https://www.uktools.com/27mm-12drive-hex-impact-socket.html
The damper rod is actually the same size hex as the rear wheel spindle (but 12-sided) so if you have an old spindle with the 27mm head in good condition but with knackered threads you can cut off the threaded part, then grind an 18mm hex onto the shank so it fits into an 18mm six-sided deep impact socket. Then just loads of 1/2" drive extension bars down the stanchion and a breaker bar on the end.
You might need an impact wrench to get them undone, IIRC I buzz gunned mine off the last time I did a set.
@finnerz89 Thankyou very much mate, just had a chat with the seller on that post and ive ordered 2 custom sized studs from him 
@calum Alright then i’ll give that a go. Cheers for your help mate, much appreciated
