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Removing fork seals, 78 GS1000

  • Thread starter Thread starter Rock
  • Start date Start date
R

Rock

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Is there a way to make a tool. I know about the pressure with the car jack method but I already have them apart as I wanted to check them out completely. Is there a way to get them out and not gouge up the aluminum? I did a search and never found anything that dealt with pulling them out other than using Suzuki's tool. Thanks.
 
I'm guessing a puller is the only way? I'll have to take them to the dealer I guess.
 
Having just gone through the chore of replacing the fork seals on my 650, here is the method I used

undo the allen bolt on the bottom of the fork leg - this allows the upper fork tube to slide freely, and will need to be done to remove it anyway

drain all the oil out of the fork

compress the top seal and remove the retaining ring

remove spring and lower valve assembly

remove dust cover and retaining clip from the fork seal

now comes the fun part

lock the lower leg in a vise, using an old tire tube or rags to avoid gouging the aluminum

get a firm grip on the upper fork tube and push it all the way to the bottom stop, then pull as hard as you can and as quickly as you can to ram the seal out. it will take several hits, but it will pull the seal out of the lower fork tube evenly.

no expensive tools to buy
 
I used the "pull really hard method" as well to remove my fork seals. However, if you use this method i would suggest that you replace the upper and lower fork bushings. You will likely scratch up the teflon coating on both of the bushings when you pull the seal. You should replace them anyway when you do the seals so you don't have to do them again real soon.
 
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