How often does one need to dissamble forks?

[karllmt]

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?

[mike_of_bbg]

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.

[hampshirehog]

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.

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.

[karllmt]

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?

[Nessism]

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.

[karllmt]

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?

[Nessism]

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.

[karllmt]

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.

[djscoutmaster]

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

[karllmt]

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.

[kochic]

This is my homemade special tool.
Marc

http://www.thegsresources.com/_forum/showthread.php?t=163720