ВeerGarage.com

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


But first, lets pay some bills:
Advertisement

  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.
    Advertisement

    But no minivans!


  17. Then I finished my beer.
    Beer

Advertisement

For legal reasons you should not try anything you see on this website.
Comments are suspended due to tons of spam.

Donate to Charity

If this site has helped you, or even if it hasn't, please help care for abused and neglected children by making a donation to The Valley of the Moon Children's Home. That's right, abused and neglected children. Visit their website and try not to cry, you cold hearted bastard. Their site talks about how they achieved their goals and built a new home, but that was years ago. They still need cash to take care of all the kids there. Breaks my heart and pisses me off.

Think: Cars are expensive, powerful, and heavy.   Before I start work, I face the possibility that I will destroy my vehicle, my own life, and innocent pedestrians' lives.   If anyone messes with a 4000 lb machine capable of 100 mph, these are real possibilities.   If I get in over my head, I call a professional mechanic.   The information on this website is provided only for entertainment purposes, and it is not intended as advice on how to service a vehicle.   For all you know I made this up.   Don`t believe everything you read on the internet.

Disclaimer: The technical information in these documents is provided without any warranty whatsoever and at no cost.   All information is in general terms and is not meant to apply to your particular situation, be current at the time you read it, or even be correct in the first place.   Improperly maintained vehicles can lead to serious injury, death, or unavoidable accidents. The author is not responsible for any errors on this site, and does not make any claim at all about the validity, safety, or veracity of the information contained on this website. Any work you choose to do or not to do on your vehicle is done at your own risk. The information on this site is not intended to serve as a replacement for professional advice, professional workmanship, dealer service, union labor, or psychological counseling.   The author disclaims any and all liability directly or indirectly arising from the application or use of any information or idea contained on this or any other web site.   By opening this page, you agree to never sue anyone ever or allow anyone to be sued on your behalf.   The appropriate professional should be consulted regarding your specific condition.    BeerGarage.com does not take responsibility for the information posted on other sites to which it links.

Copyright (c) 2007-2015 BeerGarage.Com.  All rights reserved.
Valid XHTML 1.0 Transitional

Written in Notepad2!
Last modified: 11/22/2014