Fork Questions by newbie

[Ricko19]

Hi guys,

currently pulling the forks down on my first GS in a long time, which I bought a couple of weeks ago. I need to replace the fork seals as one of them is leaking, and will be checking all the internals along the way.

I am a complete mechaical novice, and this is the most major mechanical thing I have ever undertaken! Have found some great advice on here through the search feature as well as BassCliffs site, but have a couple of pressing questions:

The bike is a 1980 GSX750ET

1. Damper Bolts - can anyone tell me the correct size hex socket to fit this bolt? I know that I don't have the right size at the moment and want to be sure to buy the right one. 6mm?

2. The bolts on these forks are badly rounded so it is difficult to tell what the correct size is, and even when I get the correct size hex, they are so badly mauled that I doubt it will work. Have ordered some replacement bolts. I have no idea how I could get them out. Any suggestions for trying to get a recessed one of these out which has a pretty much rounded off head? They are both in the same condition

3. The forks have light pitting which may or may not have contributed to my seal leaking (if it wasn't them it soon will be!) I'm not going to have the money to have them rechromed for some time. WOuld something like steel wool be ok to try and smooth it out in the meantime, or would steel wool be too harsh and damage the chrome further?

4. Embarassing question (correction - more embarassing ) Do the dust caps on the fork just pop off, like with a screw driver wedged under?

Any help appreciated

[Ricko19]

anyone?

[Big T]

1. 6mm is correct
2. You're going to learn some skills on this. If they're so rounded off the allen wrench won't grip, I think you'll have to get a small chisel and make a straight head out of the bolt top and try a screwdriver to remove it. Don't forget you have to hold the other side. To replace, it's a common bolt, just get two at Ace Hardware.
3. Steel wool and lots of rubbing may clean them up enough, If not, they'll just tear up your seals again

[Ricko19]

Thanks Big T, much appreciated

Will give the chisel a go and get rubbing on those tubes!

[BassCliff]

Greetings and Salutations!!

Hi Mr. Ricko19,

Wow, I'm really slacking. You've got 10 posts already and I have yet to slip you the "mega-welcome".

Here is your official "mega-welcome". Please take notice of the "Top 10 Common Issues", the Carb Rebuild Series, and the Stator Papers. Now let me roll out the welcome mat for you...

Please click here for your mega-welcome, chock full of tips, suggestions, links to vendors, and other information. Then feel free to visit my little BikeCliff website where I've been collecting the wisdom of this generous community. Don't forget, we like pictures! Not you, your bike!

Thanks for joining us. Keep us informed.

Thank you for your indulgence,

BassCliff

[Ricko19]

Thanks for the welcome BassCliff Have been scouring your pages for a while now, and newbies like me would be a lot more hopeless without them - good job!

This is one of the most informative forums I have ever been a part of - wish they were all this good - some others should look and learn

Great to see so many passionate people

[hillsy]

If you can't get the damper bolts out with your new allen socket, you'd be better off drilling the head of the bolt off. That way you can disassemble the forks and get a pair of vise grips on the remaining shaft of the bolt to remove it.

You'll probably need some new washers as well as damper bolts with this method.

[Ricko19]

Thanks Hillsy - had considered that as a last resort, but I'm pretty dangerous with power tools, so will try other methods first

[bwringer]

The damper bolts are an oddball thread and are NOT available anywhere else. You can get new ones from Suzuki for under $2 each.

[Sandy]

If you can't get the damper bolts out with your new allen socket, you'd be better off drilling the head of the bolt off. That way you can disassemble the forks and get a pair of vise grips on the remaining shaft of the bolt to remove it.

You'll probably need some new washers as well as damper bolts with this method.

This would be the fastest, easiest and safest way especially when working with an allen head bolt. The drill will naturally center itself. If it's a 6mm bolt then use a 6mm drill bit and only drill down the depth of the bolt head so as not to damage the aluminum underneath. If it's not quite far enough you can usually pop the head off by sticking the shank of the drill bit in the hole and giving it a sideways tug or carefully drilling a touch further. You're going to need new bolts anyway.

[Ricko19]

Just a quick question when using the 0000 steel wool on the forks - is it used dry or with some sort of liquid? If so what? Oil?

cheers