Replacement Seals

[Dr.McNinja]

Does anyone know of any alternate sources for fork seals for a 2005 GS500F? I can't bring myself to buy OEM if I don't have to. 16 dollars a seal + shipping is absolutely insane. Do all model seals work together or did the forks change at some point?

Thanks!

[adidasguy]

These are good. I've bought from him. They are K&L. Pyramid are good, but I think I like K&L a little better. You want seals and new wipers.
http://www.ebay.com/itm/SUZUKI-89-00-GS500-E-FORK-SEALS-WIPERS-/190820510791?pt=Motorcycles_Parts_Accessories&hash=item2c6dc9ec47&vxp=mtr

There are lots available:
http://www.ebay.com/sch/i.html?_trksid=p3984.m570.l1313.TR0.TRC0&_nkw=%22gs500%22+fork+%28seal%2Cseals%29&_sacat=0&_from=R40

All years the same - 1989 to present.

[zachstorman]

I ordered mine off bike bandit, $14 a pair IIRC, "bike master" I think the brand was.  Oil seals only, my dust seals were still in good shape.  When they shipped them they were labeled as something different, like 92 yamaha secca something.  But i looked up the size, 37x49x08mm, and that size fits a few different bikes (many older ones).  I have a 2005 and I installed them myself, they're workin' perfect! 
Just be warned that you will have to make a tool out of a broom handle to remove the damper rod. 

[adidasguy]

Yep - the newer forks are a real pain in the ass to work on. I made a tool out of the correct Suzuki tool (as is, it still was poor tool). That and a Harbor Freight impact wrench (Granger brand I think) and they are super easy now. If you were near me, I'd say come over and do them. I've got it down to maybe half hour for both forks.

[Dr.McNinja]

Yep - the newer forks are a real pain in the ass to work on. I made a tool out of the correct Suzuki tool (as is, it still was poor tool). That and a Harbor Freight impact wrench (Granger brand I think) and they are super easy now. If you were near me, I'd say come over and do them. I've got it down to maybe half hour for both forks.

So other than the fact they're a pain in the ass I can go ahead and order the ones you linked? Also, what is a "wiper"? Never heard of it. I appreciate your help.

[gsJack]

All years the same - 1989 to present --- except 01-02?

I had a leaker on my 02 in May 09 at 69k miles.  Didn't have a tool handy and I could get the leaking one loose without the tool so  I changed it thinking I'd do the other one later.  Later never came, yet.  So at 97.8k miles neither has ever leaked again and I still have an extra seal.   

I searched all over and couldn't any aftermarket seals for 01-02 at that time so I bought oem ones.  At that time Suzuki parts fiches listed 3 different seals for 89-00, 01-02, and 04-09.  Checked again a couple years ago and part numbers were updated and 89-00 and 04-09 were then all the same but 01-02 still had a different number and I just checked again tonight and it's still the same, 01-02 are different.

Has anyone here ever fit the present 89-00 and 04-09 common seal to the 01-02 forks? 

[adidasguy]

WIPER: That dust cap that is on top of the fork to keep gunk fro getting into the seals. You probably don't know it is there. Pry off the little cap around the top of the lower fork - you'll see it is just a cap and the seal is below it.

I'm sure I have put seals on an 01-02. I have lots of forks and know one set was a 2001, but I never paid any attention to it.
How do I identify an 01-02 fork bottom?

[gsJack]

They added the plastic fork tube shield to the 01-02 model sliders and that's probably why the seal is different since they just squeezed it in to the 89-00 design fork sliders which didn't have the shields.  Forks were the newer design Spanish made ones starting with the 04 GS-F models and they have the original 89-00 size seals.

[Dr.McNinja]

They added the plastic fork tube shield to the 01-02 model sliders and that's probably why the seal is different since they just squeezed it in to the 89-00 design fork sliders which didn't have the shields.  Forks were the newer design Spanish made ones starting with the 04 GS-F models and they fit in the original 89-00 aize seals.

Are you talking about the thing that looks like a tiny little wind deflector? My forks have that.

[adidasguy]

Dust seals are the rubber ring at the top of the fork tube. Under them are the actual seals


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[gsJack]

They added the plastic fork tube shield to the 01-02 model sliders and that's probably why the seal is different since they just squeezed it in to the 89-00 design fork sliders which didn't have the shields.  Forks were the newer design Spanish made ones starting with the 04 GS-F models and they fit in the original 89-00 aize seals.

Are you talking about the thing that looks like a tiny little wind deflector? My forks have that.

Yes, they have that fork tube shield on all 01 and later bikes including the Spanish made forks like yours.

[gsJack]

OK, finally found some dimensional information on the seals.  VESRAH lists different seals for 01-02 GS500 and also show their dimensions:

Part #: VAR3703
QUANTITY: 1 Pair
WIDTH: 8/10mm mm
INSIDE DIAMETER: 37 mm
OUTSIDE DIAMETER: 49 mm
FITMENT:
Suzuki◦GS500, 2001-2002

Part #: VAR3704
QUANTITY: 1 Pair
WIDTH: 8/9.5mm mm
INSIDE DIAMETER: 37 mm
OUTSIDE DIAMETER: 49 mm
FITMENT:
GS500E, 1989-2000
GS500F, 2004-2007

The widths are different, doesn't prove one could or could not be substituted for the other but doubt that would be true or why make both.  I'll stick to the oem seals for 01-02 GS, there are many choices for other model years.

[Dr.McNinja]

Great, thanks everyone. I'll go ahead and order those seals today. I really appreciate your help.

[Dr.McNinja]

Just bumping this topic for anyone with the same question as I have. I just got my forks done and installed back on the bike with the new seals.

For my bike (06 GS500F...I misspoke above)

http://www.ebay.com/itm/SUZUKI-89-00-GS500-E-FORK-SEALS-WIPERS-/190820510791?pt=Motorcycles_Parts_Accessories&hash=item2c6dc9ec47&vxp=mtr

Worked great and installed without a hitch. I've also got a 10 weight oil in there now. The OEM oil was basically water in comparison. I hope this helps someone else!