GSX-R 750 Pictures of how I changed the fork seals on my 1985 1986 1987 Suzuki GSX-R750 motorcycle.

But first, lets pay some bills:

  1. I got the front forks disassembled. I gave the parts a so so cleaning. In one fork tube there was a wave washers and a flat washer under the damper rod. In the other fork tube there were four and a half wave washers. This is a problem. There should be a wave washer, then a flat washer, then another wave washer in each fork tube. All these on top of that little piece of aluminum on the far right. Looks like a dealer only part.

  2. There are the parts. They go together like this. Damper rod bolt goes on the bottom. then on the inside of the outer fork tube, there is the aluminum spacer, with the washers on top. Then the inner fork tube, the small spring, and the damper rod.

  3. There's the damper rod, in the inner fork, with the washers and the aluminum spacer.

  4. And all that goes into the outer fork tube, and the bolt gets tightened with the allen wrench. Also there should be that little copper colored washer under the bolt. I tried to tighten it to 50 ft lbs. But the damper rod just spun inside the fork.

  5. SO. To hold the damper rod, we need the special tool from the Suzuki dealer. That costs umpteen fifty. OR, I can fashion my own home made special tool For nearly free, plus I run the risk of grave bodily injury! SWEET!

    I need a 27mm allen key that is three feet long. I'm sure they have that at the True Value down the road. Be right back.

  6. Strangely, they did not have the exact tool I was looking for. But they had this lag bolt.
    lag bolt

  7. All I need to do is cut it to 27mm.

  8. I marked it at 27mm, in the shape of a hexagon.

  9. I ground it down to 27mm exactly. Perfecto.
    perfect fit

  10. I tightened it onto this threaded rod extension. I had this rod from doing the same thing on the GS500 a few years ago. The damper rods are different sizes, though, so I had to make this new one.
    threaded rod

  11. I held the extension securely in a wrench in a vice on the table.

  12. Then I could tighten the damping rod to 50 ft lbs. I don't have an allen socket that size, so no torque wrench. So I went to "pretty freakin tight without smashing the aluminum under the bolt."
    loosen damper rod

  13. Anyway, then I put the progressive fork springs back in.

  14. Remember when I measured the 41mm OD forks?
    Measuring forks

  15. Well, an exhaustive search of the True Value got me this:

  16. It is a connector for two pieces of PVC. It is 41.5mm ID, except for this little berm in the middle.
    PVC connector

  17. I used my deburring tool.
    deburming tool

  18. Et, viola! Deburmed.

  19. I greased up the oil seal for reassembly.

  20. All the parts on the fork in order. metal slide bushing, washer, oil seal, washer, seal driver.

  21. It turns out it is the metal bushing that needs to be seated. I greased the bushing, and then it went together super easy. I just pushed on the PVC seal driver, no hammering necessary.

  22. Then the circlip.

  23. Then some grease on the dust seal.

  24. The dust seal pops in, and hey presto. Done.

  25. Oh yeah. The fork oil. I found this Suzuki 15w online. This is the last bottle on earth, so don't even try. Each fork takes about 400ml. So out of 1000 ml, 1 L, two of these, I have about 200 ml left. That is roughly 14 oz per fork.

  26. 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!

  27. Then I finished my beer.

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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. does not take responsibility for the information posted on other sites to which it links.

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