Front Fork Rebuild

[Tech73]

OK, I have taken the forks apart and have gotten some of the parts to rebuild them. I was wanting to know if it was necessary to to buy part #10 and #8 on the Parts Fiche. They call these #10 Piston and #8 Metal Slide. Mine are there but the crome has been worn off them. Is there a point in replacing them?

http://s104.photobucket.com/albums/m...nt=2156_55.gif

I have rebuilt almost everything on this bike other than the motor.

 

[Johno]

The link doesn't work for me!

 

[bonanzadave]

Yes. Just do it . Ive been chasing a high speed handling issue and replacing the fork bushings has helped more than anything else ive tried.

 

[Guest]

What are the forks on? And yeah replace everything including the metal slides. Should be two pairs. One set at the bottom of the tube sliders and a set just under the seals. You said the chrome was wore off? Those are coated with teflon, never seen chrome.

 

[tkent02]

The Teflon was new in about 1980. Technology marching on and all.

 

[Guest]

The Teflon was new in about 1980. Technology marching on and all.

The sets of slider bushings I bought to rebuild the 1100E forks were still teflon coated. Then again Tech73 doesn't say what his bike is. His link didn't work for me as well.

 

[Tech73]

Sorry guys, It's a 82 GS1100ez. They looked crome to me but you guys know more about this stuff than I do so if you say they're teflon then that's what they are.

Someone had these apart before and didn't put some of the parts back in. It was missing the two little leaf spring washers and the reg washer between them.

The link was just to the parts fiche so you could see what I was talking about.

Thanks for the advice guy's, I'll go a head and order them.

 

[Guest]

Sorry guys, It's a 82 GS1100ez. They looked crome to me but you guys know more about this stuff than I do so if you say they're teflon then that's what they are.

Someone had these apart before and didn't put some of the parts back in. It was missing the two little leaf spring washers and the reg washer between them.

The link was just to the parts fiche so you could see what I was talking about.

Thanks for the advice guy's, I'll go a head and order them.

Just be really careful when you install the metal sliders ( I call them bushings) into the lower leg. The bushings are split as to make it easier to install. Use a block of wood that fits over it and tap in. Use anything else like a punch or something metal, slip and mar the finish on them you start over by buying a new set.

 

[Tech73]

Here are the one's out of my forks.

 

[Guest]

Here are the one's out of my forks.

Yup replace them. The larger one is the one that goes on the slider tube and shows extensive wear on the outside. The smaller one goes into the fork leg and still looks good from what I can see inside. Pretty sure that is right, I just looked at my old ones this morning lol. It is time to change them regardless.

 

[bonanzadave]

Old & New (mine)

 

[bonanzadave]

Installed

 

[bonanzadave]

Even though the new bushings seemed to help the high speed wobble a bit I believe the tolerance could be a lot tighter.

(click the pic)

 

[Tech73]

Thanks for the advice guys. I've ordered them and hopefully have this thing going soon.

 

[Tech73]

All my parts finally came in so now I can go about putting these together. I have progressive springs to put in also.

Dave, how much oil did you put in your 1100? I went by the book before reading the progressive stuff and put 246ml. It started leaking out of the little hole in the stanchion so I poured it all out and left it upside down over night to drain more out. I have read on the progressive paper work that it should measure 140mm (5.5inches) from the top.

I read on Flyboys fork rebuild thread that he put 241cc (ML is the same) and measured 140mm with the fork fully collapsed. If I do this then oil will come out of that little hole again. Advise needed

 

[Tim Tom]

IF it is the hole I am thinking of, there should be a screw and little rubber grommet in that hole. It's designed to function as a drain to allow the oil to be changed without total disassembly.

Check the parts fiche below. Is it the hole near parts 25 & 26?
http://www.bikebandit.com/1982-suzuki-gs1100e/o/m21371#sch269708

 

[Tech73]

That's not it Tim Tom. Maybe I should have called it the slider. It's near the top. The air coupler goes over it between the steering stem . I'm at work now so can't be on here much.

 

[Guest]

There is one hole at the top one on each of the sliders. those are for the air system, apparently you either don't have it installed or your sliders are too far up or down. IF you didn't reinstalled the air system then you need to seal off those tiny holes with something.

 

[bonanzadave]

I used a qt of Suzuki 15wt I got from Boulevard. 8oz in each fork. I added the oil after the forks were reinstalled on the Bike so I dont know if was weeping out the air holes. I dont think so.

 

[Tech73]

I went by the progressive instructions and filled them with the tubes fully compressed and level. Measured 140mm (5.5 inches) from the top of the tube to the top of the fork oil and just kept a finger over the little air hole. I have them installed on the bike now but need to put the wheel back on tomorrow.