Removing fork seals is a pain in the A**!!!

[Guest]

I've tried a screw driver, a chisel (to pry like a screw driver) with pipe for leverage and now heating them with a torch... still stuck and now the outer tube is discolored! WTF! I'm trying not to buy the seal removal tool. It doesn't look like it'll be any better than what I've got, but I may have to. This afternoon project has turned into days...

Anybody got any other suggestions?
And, why are they so stuck???

[rapidray]

FIRST thing....do you have a FACTORY Suzuki shop manual? If not, that is your first thing to fix!!! After that, it is self explanatory. Ray.

[JEEPRUSTY]

There a lot of youtube vids on the process
as RR said do dload the manual from the basscliff site.

[bonanzadave]

Anybody got any other suggestions?

Did you remove the Damper rod bolts and separate the upper tube from the lower fork ?

http://members.dslextreme.com/users/cbsaunders/gs/Fork_Seal_Replacement_GS850GT.pdf

[TheCafeKid]

Did you take the circlip that holds the seal in out? They're pretty tough to get out if you don't do that. .

[Griffin]

FIRST thing....do you have a FACTORY Suzuki shop manual? If not, that is your first thing to fix!!! After that, it is self explanatory. Ray.

I will never understand why anyone would ever try to work on an old bike (or car, or boat, or airplane) without the specific shop manual to use as a guide. There is nothing difficult at all on these bikes, as long as you know what process to use.

Without a mnanual, you might as well just use a hammer and some TNT on it.

[GS750cafe]

Wow, lot of support this time.
Yes I have a manual, but it's the Clymer
Yes I removed the allen bolt and separated the upper tube and lower fork.
Yes I removed the circlip.
I guess I'll download the FACTORY Suzuki manual before I get out the hammer and penolite!

[SqDancerLynn1]

Sounds like you have it all apart right? Drill a small hole in the metal part of the seal. Thread a long screw into the seal and lever it out with a hammer or pry bar. put a piece of wood over the fork to protect it..

[SVSooke]

Usually they are not that bad.My Honda project bike has the exception.Not out yet.

[GS750cafe]

Drill a small hole in the metal part of the seal. Thread a screw into the seal and lever it out with a hammer or pry bar

Might have to try that. Sounds a little touchy though... one slip with that drill bit!

The FACTORY Suzuki manual says "replace oil seals found in damaged condition"...
well they are pretty damaged now!!!

[TheCafeKid]

Seal puller at autozone or harbor freight may be $10. They're handy to have when all your buddies want you to do their forks

Just be mindful you don't nick up the seal seat or anything.

[cal_look_zero]

http://www.google.com/products/catalog?q=diamond+cutting+wheel&hl=en&safe=off&rlz=1C1CHFX_enUS444US444&prmd=imvns&bav=on.2,or.r_gc.r_pw.r_cp.,cf.osb&biw=1280&bih=685&um=1&ie=UTF-8&tbm=shop&cid=10073202087606141680&sa=X&ei=4rubTsuQHLGGiQKjlfXNDQ&ved=0CJQBEPMCMAI

I've done 7 sets of fork seals by using these little diamond cutting wheels on a die grinder. The size and angle makes it so that I haven't ever touched metal on the seal seat, but cut away enough of the seal to be able to pull the remainder easily.

[BassCliff]

Hi,

There are TWO fork seal replacement guides on my little website. Have a look to see if they might help.


Thank you for your indulgence,

BassCliff

[bccap]

What year 750 is it ?

[GS750cafe]

Thanks guys. I'm gonna spend some time on it today. I checked your guides BassCliff; thanks for compiling so much info in such an easy to read format! Very helpful - a lot more helpful than "read the manual"!

The bike is a '77.

I'll see what I get accomplished today.