Steering Stem Bearings and Fork Oil Change

[GsRocket]

I need to replace the steering stem bearings and fork oil seals on my 81 GS450. does anyone know of a good resource to guide me through this. I've wrenched on this bike in many ways and i'm positive i could probably do it without one but i dont want to get halfway through and realize i need a "special tool". I'm pretty sure i can get the special nut on the steering stem head off with a screwdriver and a hammer. anyone advise against this?

[hampshirehog]

For fork seal replacement have a look at Cliff's 'little old site'. There's a good turorial on there. It's an easy enough job so you will be able to do it I'm sure.

Similarly changing the head bearings is easy though getting the bottom race off can be a bugger some times. Yes, you can undo that nut with a screwdriver and a hammer - most people use that technique. If it's tight and seized use a blunt driver to save messing up the finish on the nut.

[Johno]

Similarly changing the head bearings is easy though getting the bottom race off can be a bugger some times.

My experience was that it was all pretty straight forward except the removal of the bottom race.

An engineering mate of mine carefully cut it with an angle grinder.

[Steve]

You can use a Dremel tool with a large cut-off wheel to cut into the race twice, about 1/4" apart.
Don't worry about nicking into the frame if you go too deep, it won't hurt anything.
After removing the small piece, the race will literally fall out.

Since pictures speak louder than words, here is how it looks after being cut:


Here is why I had to change the bearings:


.

[GsRocket]

So i have everything off, and the real problem is the bearing set on the bottom wont come off. It was already bent as you can see in the first pic which may be the problem. I resorted to hammer and screwdriver and it ripped the rollers off but left the inner race (second pic) or whatever it would be called. heres pics.
before

after


any advice on how to get this sucker off. i dont have a dremel yet, i tried hammer and chisel but it wont budge, and i can't drill through it.

[chirobo]

Cut it with dremel or angle grinding wheel. Many other ways..heat to expand outer band. Thinking ahead, after removed, freeze steering shaft, and slightly heat bearing to put new one on...

[Erki]

I carefully cut mine off with a cut off wheel as well.

[FLHGSRay]

A chisel and hammer will break it.

[GsRocket]

Thanks for the advice guys, picked up a portable dremel for 70$ that did the job. And i'm sure i'll be using this little guy for all kinds of stuff now, pretty handy. Total for this job i'm at $140 and the shop wanted $450...

Another thing though, my fork seals seem to look good from the top but i was going to replace them anyways while i was in here. However the bottom allen bolt on the forks is stuck pretty good and at the risk of it snapping, like one of my rusted header bolts did earlier, i dont want to force it. any ideas to coax it out? or should i just put all my force on it

[7981GS]

However the bottom allen bolt on the forks is stuck pretty good and at the risk of it snapping, like one of my rusted header bolts did earlier, i dont want to force it. any ideas to coax it out? or should i just put all my force on it

Hit the allen socket with an impact gun and out it will come.

Daniel

[hampshirehog]

Give that allen bolt a good whack with an impact bit. Make sure the bit fits tight otherwise you'll be drilling the thing out.

[GsRocket]

I dont have the right size allen bit, just the wrench... It's very rare that i would need them for my bike so i've never bothered. any way to test the seal without taking the inner tube out?

[koolaid_kid]

I dont have the right size allen bit, just the wrench... It's very rare that i would need them for my bike so i've never bothered. any way to test the seal without taking the inner tube out?

My advice: you are already in there. Spend the extra time/money to get the proper tool and do everything now. That seal may be 30 years old, btw.

[7981GS]

$7.00 tops at Sears or your local hardware store for a 3/8" drive Allen tipped socket.

Daniel

[GsRocket]

Ha i just stripped my extension for my drill trying to get out a stripped screw. I guess i will be makin another run so ill pick up the allen bit

For the problem at hand:
Last time the mechanic took off my exhaust he must of bent the header bolt putting it back... exactly why i dont go the mechanics anymore.
It came out partway and got stuck and snapped the head of the bolt off(it was rusted up) so i had a couple options

First i used the reversed drill bit method with no success, then i grabbed the dremel and made a slot in it. Tried by hand with a screwdriver and a vicegrip but it wouldnt budge so out comes the drill... but it only made it worse.

I'm thinking my only other option is to drill it out and hope theres enough untouched thread to still secure my pipes. Suggestions?