SUZUKIPictures of how I changed the front fork oil seals on my 89-09 Suzuki GS500 motorcycle.

But first, lets pay some bills:

  1. Went shopping:
    1. New fork seals
      Fork Seals
    2. 5/8 threaded bar
    3. 4X 5/8 nuts
    4. 2X 5/8 lock washers
    5. 1.5" ID PVC Pipe
    6. tools

  2. Got the forks off, removed the springs and drained the oil as described in the Fork Oil page in the menu on the left.

  3. Removed the pinch bolt and the axle bushing to give access to the damper rod bolt hole.
    Pinch Bolt

  4. With an allen wrench and a long socket and a socket extension to give leverage on this side,
    allen adapter

  5. and with the "special tool" on this side, I unscrewed the damper rod bolt. The special tool is the 5/8" threaded rod and 5/8" bolts and lock washers. The bolts are 15/16" on the outside. This effectively makes a giant 15/16" allen wrench. My local hardware store sold the threaded rods in 6' lengths. Too lazy to cut it down, and this worked fine.
    damper rod

  6. A small screwdriver popped off the dust cover.
    dust cover

  7. That same small screwdriver worked fine to pop out the oil seal retaining clip.
    oil seal retaining clip

  8. A few hard pulls and the fork comes apart. This is the inner fork tube with the oil seal on and a giant washer beneath that.
    inner fork tube

  9. The old leaking seal slid all the way up the tube and off. Here is the old one on the left, the new one on the right. I can see no defect in the old one, but it leaked quite a bit.
    fork oil seals

  10. I slid on the new seal in the same orientation as the old one. Then I put the inner fork tube back into the outer one. To seat the oil seal, I put the 1.5" PVC pipe over the inner fork tube and hit the PVC pipe a few times with a plastic mallet. The fork is way down at the other end of the picture in the vice there. My local hardware store sold the PVC in 10' lengths, and you get the idea.
    PVC pipe

  11. Here is the new seal seated well inside the outer fork tube.
    oil seal seated

  12. Using that same small screwdriver to reinstall the fork oil seal retaining clip.
    oil seal retaining clip

  13. Popped the dust seal back on.
    dust seal

  14. Then I reassembled the forks, also described in the Fork Oil page in the menu on the left.

  15. Rode around for a while and checked the seals. No leaks.

  16. Next I sold out to make 02ยข so I can fulfill my lifelong dream of owning a 1986 944 with blown head gaskets.

    But no minivans!

  17. Then I finished my beer.


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Last modified: 11/22/2014