82 GS650GLZ Front fork dissasembly

[Anonymous]

Starting a project of love on a recently aquired gs650 trying to replace fork seals but cant seperate the 2 tubes. Everything is apart and unbolted tried inserting 1/2 inch threaded rod and nut but sleeve inside just spins.
any help or suggestions would be appreaciated.

[Anonymous]

fork seals

Just recently replaced the seals on my GS750. I went so far as to get the 1/2" rod with a nut welded to the bottom the hold the inner tube, lo and behold there was no place for the nuts to grab, ompletely round.
I remembered someone, on this site I think, saying they had used a broom handle shaved down to fit into the tube to stop it from turning. I tried it and it worked like a top, easiest job I ever did, it might work for you....Mike

[Don Lobacz]

A 3/8" or 1/2" impact on the bottom allen will usually zip it right off.

[Anonymous]

Thanks for all the info the bottom bolt came out ok and the top spring and peice below that are out. all I have left is the two tubes joined together and the fork seals still in place. When I insert the 1/2 inch rod into the sleeve it sits in a washer looking affair and the washer spins around but I cant get the final pieces apart. I guess I,m missing something simple, I have a manuel on order but any help in the mean time would be great .

[Anonymous]

slide hammer

If I understand you correctly all you've got left to do is remove the snap ring just underneath the dust seal and use the upper (smaller) tube as a slide hammer. After 3 'slaps' (on mine anyway) the dust seal and the washer below it should come out with the top tube.
Just do one at a time so you don't get the parts messed up and take note the way the seal is posiioned in regards to the garter spring.
Make sure that you check the copper washer under the bottom bolt and use blue Loctite on the bolt to prevent it from backing out and it doesn't have to be exceptionally tight, you're not holding together a tank :-)...Mike

[Anonymous]

the snap ring was already out one of the first things I removed tried using tube as slide hammer but wont budge my manual is on order maybe I'll have to wait.

[SqDancerLynn1]

It sounds like you have it appart it is just stuck, Put the allen bolt back in Just a few threads and tap on it with a block of wood and a hammer

[Dark Jedi]

A future tip:

Those seals will be hell to seat. Search for tips on seating them, and what people have used to seat them. I used a big washer that looked just the right size, and an old piece of iron tube as a slide.

My washer got cocked a little to the side, and I ruined the mating surface.

Just be careful, and make sure your tool is either the proper one, or a perfect fit.

[Mr. Jiggles]

On my 1100, a 1-1/2 inch ABS pipe worked perfectly to set the seals. A couple of taps with a hammer was all it took. Just be sure to oil the seals before putting them on.

Jeff

[Anonymous]

RE: using an impact wrench on the allen bolt..

My first tube came out with some work.

On the second, the impact wrench stripped the allen head in no time flat. The 8mm hex bit was new, and fit tight in the socket. I have yet to get that bolt out- I was able to remove the oil seal without complete disassembly by screwing some sheetrock screws in the top of the old seal to use as pulls.

Anyone have any tips on removing the stripped damper rod bolt?

[Anonymous]

try this

If you know anyone that's a welder take it to them and get them to weld a nut to the top of the bolt. Usually this will heat up the bolt enough to break it free if it's been Loctited and it'll give you a place to wrench it from.
A note of caution, BE SURE that you put your ground clamp directly on the nut you're welding, you don't want any stray current arcing up the tubes. Also cover the tubes with a wet rag to prevent spatter sticking to the exposed aluminum, looks like hell when it rusts.....Mike