1981 GS 650E How to Remove the Spring Stopper Clip on Front Forks?

[Kiwi Canuck]

I need to open up my forks to replace the fluid, and can't figure out how to remove the clip under the rubber top cap.

There is a "spring stopper' held in by a clip, shown in section; Chassis 7-12 of the manual, it doesn't go into detail on how to remove the clip.

I need to hold the spring stopper down while somehow digging in there to remove the clip, is there a tool to do this or what?

Thanks

David.

[Sandy]

If you mean the snap ring I usually use a pair of fine tip needle nose pliers to start it and a small flat blade screwdriver behind the clip to keep it from popping back in groove, while pushing down on the stopper with a 1/2" extension I then grab one of the holes with an oring pick or heavy spring hook and just pull it out. The spring stopper usually has an indent in it to center the extension, a #3 phillips screwdriver also works good as it's got a good size handle to grab and push with. I do this before removing the fork legs, the motorcycle makes a good vice at this point. Some might use proper snap ring pliers but I find due to dirt or other contaminants they don't compress the snap ring enough to evenly remove it and you end up having to pick away at anyway.

[Nessism]

Compress the spring a little by pressing down on the cap and then dig out the clip using a micro screwdriver.

[SVSooke]

It's not a "normal" C clip with "ears" to use pliers.Have to get behind it with a screwdriver like Nessism says.It's a PITA to do by yourself.Just to save a cent or 2

[tom203]

I had good luck with a bigger version of tool in attached pic . It pressed down and held the cap so I could pry out the snap ring- wear safety goggles!image.jpg

[Steve]

I have seen at least three variations on spring retainers:
1. a smooth, simple, round wire
2. a wavy wire
3. an internal snap ring, which has holes in the ends that require snap ring pliers.

I have the feeling that you have #1. As others have mentioned, press down on the retainer. It only has to be 1/8" or so. Find the gap between the two ends of the wire. Use a pick or a small screwdriver to pull one end away from its resing place. While keeping that end free, work your way around, pulling the ring out of its groove in the fork tube.

Putting it back in is a bit easier. After installing the oil and spring, put the cap in place, there should be enough room to put the snap ring just above it. Push down on the cap to get it below the groove, push the snap ring down until it snaps into place.

.

[Kiwi Canuck]

OK thanks for the posts, and the reminder about safety glasses, I already have the forks out of the bike so I'll need to clamp them in the vise, I'll tape the legs up and use soft jaws to prevent causing any damage.

Now that I've cleaned all the rust out it looks like I have the straight round wire spring clip as I didn't see any sign of a hole for circlip pliers.

Hopefully they co-operate, I'll let you know how it goes.

BTW really appreciate the quick responses and the depth of knowledge on this site.

Cheers,

David.

[Kiwi Canuck]

OK I figured out what was up and why I couldn't see how to disassemble the stoppers, both stoppers were seized solid with rust, they wouldn't move at all so I mounted them in the vise vertically and sprayed some penetrating oil in the recess, covered the opening with a rag and used an old #3 phillips and tapped on it until I felt some movement.

That got the whole thing moving and after cleaning out the rust was able to depress the stopper and pry out the clip.

The rust was so bad the rubber o-rings were rusty, I'll need to add those to my latest order with Parts Outlaw.



David

[Steve]

... BTW really appreciate the quick responses ...

Huh?? Quick responses?

It took over half an hour for the first one, then about an hour for the next four.

We have done better than that.

.

[Sandy]

Huh?? Quick responses?

It took over half an hour for the first one, then about an hour for the next four.

We have done better than that.

.

Yeah, where were you? LOL.