Removing front fork caps GS1000.

[Suzuki mad]

Tricky problem GSr's.

My 1981 GS1000E has blown both front fork seals.

I need to get the top tube cap off that holds all the air system. These have no spanner hold and I do not want to use a set of mole grips that will leave teeth marks or anything that may crack or break the cap.

According to Suzuki these caps are no longer available as parts!!!!

Any top tips before I admit defeat and take the forks to the garage and let a monkey work on them.

I am having to replace the tubes too hence the complete strip of the forks.

Cheers
SM

[Agemax]

you will find a 17mm open ended spanner will work on those for tops i believe.

[Suzuki mad]

I'm guessing that its best to leave them bolted in the yokes (tripple trees) to loosen them off. They've only got an 'o' ring underneath to seal them so shouldnt be too tight. (These seem very tight hence the mole grips idea and I have no idea how long they have been on the tubes.)

[sharpy]

loosen the top clamp but of course leave the lower clamp up tight then undo the cap. Have you thought about upgrading to just springs and having no air in the system as it puts added pressure on the seals

[Suzuki mad]

loosen the top clamp but of course leave the lower clamp up tight then undo the cap. Have you thought about upgrading to just springs and having no air in the system as it puts added pressure on the seals

NO!!!!!

I like them just as they came out of the factory. Sad but its how I like my bikes, standard.

[chuck hahn]

Just break the tops loose and remove the forks but dont disassemble them.

Next, use the impact to get the allen head out from the bottom and THEN you do the disassembling of the cap ect etc. An air impact work perfectly for the allen head bolt removal. Blaht Blaht and its out. And there shoulkd be drains at the bottom. open them and pump the fork in a bucket to get most oil out. Stick the fork in and lean down on the top and pump them till they spurt air, and remember that if theres air in them when you open the drains..its comming out like an oil squirt gun so relieve any air pressure before opening.

[1980GS1000E]

loosen the top clamp but of course leave the lower clamp up tight then undo the cap. Have you thought about upgrading to just springs and having no air in the system as it puts added pressure on the seals

My experience is that having air in the system avoids leakage. My fork seals will weep with zero air pressure but don't at 11 psi.

[850 Combat]

My brother used a 12 volt air compressor to blow the seals out, and changed them without dismantling the forks. It was an 1100G

As to air in the forks and seals blowing, I typically run in the high 20's to low 30s PSI in my forks without any problems whatsoever, and have done so for the best part of a decade. This is on a decent number of bikes.

[azr]

My experience is that having air in the system avoids leakage. My fork seals will weep with zero air pressure but don't at 11 psi.

are you using progressive springs?

[Suzuki mad]

My brother used a 12 volt air compressor to blow the seals out, and changed them without dismantling the forks. It was an 1100G `

I could shove a screw in the seal and pull them but the tubes have pitted so badly that putting a new seal on will just ruin then before I can ride the bike so I need to change the tubes too. That means the whole thing has to be broken down.

I've been putting it off for a year now......

[1980GS1000E]

are you using progressive springs?

What ever was in the bike when I bought it used. What diff would it make as to seals?