New fork seals, new fork tubes, still leaking, HELP

[Anonymous]

Hello All,

I wonder if any of you can be of help. I have a 1978 GS550, that had rusty pitted fork tubes when I bought it. Oddly enough they didn't leak then. I ordered brand new fork tubes from a place that specializes in fork tubes (Forks By Frank). I ordered the ones for my model but when they arrived the did not fit the lower fork legs (too long). I called the shop, and I was told that they made the tubes for the factory specs of a 1978 GS550 (Base model), but that they were not surprized as apparently Suzuki was notorious back in the old days for making changes mid year, and for different markets (I have a Canadian Bike). So I sent back the tubes, along with my old tubes, and they remade tubes baised on the old ones for no extra charge.
Another strange thing I encountered was that my factory seals had washers underneath them that looked as though they were some sort of oil scraper. I damaged one of them when I removed the seal. In the 1977 factory suzuki manual I have, it shows only a seal, no washer.

When I replaced the seals I used Genuine Suzuki seals that I ordered but I noticed that they fit the tubes, but didn't seem to fit as tightly arround the tube as I would like. After all was said and done both fork seals leaked! I was frustrated and left them that way (Leaking)
I've just ordered new aftermarket seals, and I noticed that they are supposed to fit 1977 - 1980 gs550 and 550e bikes. So what gives? Did I get the wrong seals from Suzuki? Why was there a spacer below the factory setup that didnt show up in the manual? Will I ever get the forks to stop leaking???

What are your thoughts and experiences?

[graham harron]

I am no expert on forks but i did mine and they seem to be ok .The seals should be tight on the tubes as i remember, about the washer if it was there i highly recommend putting it back exactly the way suzuki had it . check some of the drawings on bike bandit i am sure you will come up with the part.

[Anonymous]

Wow, thanks for the bike bandit tip. The have all the diagrams AND the part numbers If only I had known about that two years ago when I had the bike all apart.

[SqDancerLynn1]

Their is a bettersite

http://www.alpha-sports.com/suzuki_parts.htm

Not knocking bikeBandit I have purchased alot of parts from them Their listing no longer gives you the suzuki part # just an in house #

[HiSPL]

Try very hard not to pound your new seals in. If it takes more force than just pushing with your fingers then something is not lined up right. pounding in new seals can make them leak.

[Anonymous]

Did you mike the new tubes to see if they are the same diameter as the old ones?

[Anonymous]

Did you mike the new tubes to see if they are the same diameter as the old ones?

Yes they are the same diameter. I guess I'll wait and see when the new seals come in to see how tightly they sit on the tubes. The original seals were in very tight. it was a pain to get them out. I did have to pound the new ones in. I'm guessing that I got the wrong seals.

[Anonymous]

Did you mike the new tubes to see if they are the same diameter as the old ones?

Yes they are the same diameter. I guess I'll wait and see when the new seals come in to see how tightly they sit on the tubes. The original seals were in very tight. it was a pain to get them out. I did have to pound the new ones in. I'm guessing that I got the wrong seals.

Very possible. They should be tight.

[skreemer]

what a huge coincidence... I have an '83 GS550E and my front fork down tubes are marked "Forks By Frank".... and they constantly leak. I checked the specs against what's in the clymers and haynes I have and they match. I out new fork seals on this winter and they are seeping pretty bad. I'll watch this thread with great anticipation.

[skreemer]

HA HA... I found the guys number... 847-475-1003 was the number that was posted... this means the guy is more or less in my area... I'm going to give him a call and see what he suggests.

***edit to add***

Hmm conflicting info a bit... same "name" different phone number...
Frank's Maintence and Engineering
312-869-6792
945 Pitner
Evanston, IL 60202
AKA Forks by Frank
parts--forks

***edit again***
here's the website


http://www.frankmain.qpg.com/

[KGB]

If thne bushing are gone or "used up" then you can continue to put in seals and they will leak.
Check the bushings also.








After 2 sets in my E I need to replace the bushing s also.
Learn from my mistake, do it all at once.

[skreemer]

Stupid question...

If the forks call for an amount of air pressure to be in them will it require the air to form a seal?

[Anonymous]

Well it looks like I found the problem. When I replaced the forks the first time they were Suzuki parts, and they came in a bag. I installed them the way that looked right (The Manual didn't say that there was a top and a bottom). The second set of seals that I bought were aftermarket seals, and they came with instructions. The seals I had installed were UPSIDE DOWN! I installed the new aftermarket seals right side up and voalla, no leaks. So for anyone out there installing new seals, make sure the side with the tiny writing on it goes up.

[back_online]

Mine have leaked for sometime, I wish I had a step by step photo procedure like they have for the carb rebuild somewhere. :?

[bwringer]

If someone will document (or has documented) their fork seal repair/replacement with photos and/or words, I will be happy to make it into a web page and add it to the collection:

http://bwringer.com/gs

PM me for instructions if you have anything to contribute.