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How often does one need to dissamble forks?

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    How often does one need to dissamble forks?

    I have an '80 GS750E. I had the dealer's shop replace the fork seals a few years ago. (had to remove the forks from the bike and only bring in the forks - they will not service bikes over 20 years) When I picked up the forks, I was warned that the seals might start leaking again because the inner tube has pitting. And sure enough, within a year the left fork started leaking.
    I have acquired a spare set of forks, that were advertised from the same bike; but they are not, as they have the air nozzle at the top, mine do not.
    I am aware that I need to have the "special tool" to remove the inner tube.
    My first question; how often will I need to remove the inner tube, and therefore is it worth it for me to make or acquire the "special tool." Or does anyone near by have one I can borrow?
    Second question; compatibility. Do most of these bike use the same forks and/or inner tubes?

    #2
    Check the rest of the dimensions of the forks. The air cap is just a cap. I wet sanded a few small pits with 600 grit and it has not started leaking again.

    Also, there is no need to buy a special Suzuki tool: do some forum searches. There are a number of options depending on the size of your forks. I used a wooden broom handle. You can also use spark plug sockets with extensions, or some threaded rod and nuts. The tutorial on BassCliff's site shows his custom tool IIRC.

    Comment


      #3
      Originally posted by karllmt View Post
      My first question; how often will I need to remove the inner tube, and therefore is it worth it for me to make or acquire the "special tool." Or does anyone near by have one I can borrow?
      You only need to remove the tube when you replace the tube (though I think it is easier to remove the tube when fitting new seals and most people go that way). For the 'special tool' try a broom handle - works 99.9% of the time.


      Originally posted by karllmt View Post
      Second question; compatibility. Do most of these bike use the same forks and/or inner tubes?
      No. There's quite a range of different parts - some swap over easily and some don't.
      79 GS1000S
      79 GS1000S (another one)
      80 GSX750
      80 GS550
      80 CB650 cafe racer
      75 PC50 - the one with OHV and pedals...
      75 TS100 - being ridden (suicidally) by my father

      Comment


        #4
        special tool

        OK, So the "special tool" has a nut on the end that fits into somthing like a big allen socket inside the tube? And a broom handle would but pressure on that to keep it from turning as one wrenches the allen on the bottom outside. Is that the way it works?

        Comment


          #5
          Originally posted by karllmt View Post
          OK, So the "special tool" has a nut on the end that fits into somthing like a big allen socket inside the tube? And a broom handle would but pressure on that to keep it from turning as one wrenches the allen on the bottom outside. Is that the way it works?
          Yes. I use a spark plug socket on a long extension. It's pretty easy work to replace seals or open the forks up in general.
          Ed

          To measure is to know.

          Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

          Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

          Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

          KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

          Comment


            #6
            Originally posted by Nessism View Post
            Yes. I use a spark plug socket on a long extension. It's pretty easy work to replace seals or open the forks up in general.
            I like the extension socket idea, but I'm confused. A spark plug socket would not fit INTO what is down there. Or am I missing something?

            Comment


              #7
              Originally posted by karllmt View Post
              I like the extension socket idea, but I'm confused. A spark plug socket would not fit INTO what is down there. Or am I missing something?
              Many spark plug sockets have a hex on the bottom, which matches what's in the forks. You put the socket onto your extension backwards then use that to hold the damper rod while you turn the allen screw on the bottom.

              There are lots of different threads here in the archives showing photos and such. Please try the search functions to glean more info if you still don't understand.
              Ed

              To measure is to know.

              Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

              Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

              Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

              KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

              Comment


                #8
                Originally posted by Nessism View Post
                Many spark plug sockets have a hex on the bottom, which matches what's in the forks. You put the socket onto your extension backwards then use that to hold the damper rod while you turn the allen screw on the bottom.
                Backwards! Got it.

                Comment


                  #9
                  Originally posted by karllmt View Post
                  I have an '80 GS750E. I had the dealer's shop replace the fork seals a few years ago. (had to remove the forks from the bike and only bring in the forks - they will not service bikes over 20 years) When I picked up the forks, I was warned that the seals might start leaking again because the inner tube has pitting. And sure enough, within a year the left fork started leaking.
                  I have acquired a spare set of forks, that were advertised from the same bike; but they are not, as they have the air nozzle at the top, mine do not.
                  I am aware that I need to have the "special tool" to remove the inner tube.
                  My first question; how often will I need to remove the inner tube, and therefore is it worth it for me to make or acquire the "special tool." Or does anyone near by have one I can borrow?
                  Second question; compatibility. Do most of these bike use the same forks and/or inner tubes?
                  How much did the stealership charge you to rebuild your shocks

                  Comment


                    #10
                    Originally posted by djscoutmaster View Post
                    How much did the stealership charge you to rebuild your shocks
                    Sorry, I don't remember. I think I paid $50 for labor, 6 years ago. I pre-ordered, and pre-paid for the parts. I was going to do it my self, but the "special tool" in the service manual scared me off. Now that I have a little more experence in wrenching, I'm going for it.

                    Comment


                      #11
                      This is my homemade special tool.
                      Marc
                      https://www.thegsresources.com/_foru...ie_twisted.gif AIR COOLED MONSTERS NEVER DIE https://www.thegsresources.com/_foru...ie_twisted.gif
                      1978 GS1000C X2
                      1978 GS1000E X2
                      1979 GS1000S
                      1979 gs1000
                      1983 gs400e

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