FORK SEAL REPLACEMENT...who's got the goods?

[GS Paul]

Hey all,

Need to replace my fork seals...bummed because I just went in there not too long ago to put in progressives.
Anyhow...I'm remembering how tough it was to get my friends Gixxer seals out. How hard is the swap on the GS500 (2001)? ....besides getting into the forks.
Dust seals need to change too? Wipers?
All help is helpful.
Cheers!
Paul
(Ps. Out of cell range this week sometimes. Forgive me if I don't respond quick....but I will )

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[snOhio]

beer garage tutorial linked in the wiki is on point.  i had never done seals before, first fork took 1.5 hrs and the second took 20 minutes.

[Blueknyt]

  http://gstwins.com/gsboard/index.php?topic=16318.0 

[adidasguy]

One important thing when you reassemble the front end....

There is a "floating" spacer at the bottom of the right fork. That spacer should slide back and forth easily. Once everything is assembled and checked out, you then tighten the bottom bolt that holds that spacer in place. The purpose of it is to let the forks self align. If you tighten that spacer before assembling things, you will torque the forks when you tighten the axle.

With the forks torqued a little so they are not in straight alignment, one or both of the seals will wear out prematurely.

[bryan88]

Please elaborate Adidasguy, are you talking about the axle pinch bolt? Thanks.

[adidasguy]

The axle goes through a spacer on the right fork. That spacer is held in place with a pinch bolt. That must be loose when you install the wheel and tighten the axle. after the wheel is on, then the floating spacer will be where it wants to be and you can tighten the pinch bolt.

actually, before that you tighten the fork brace. Fork brace should not be tightened until the wheel is in place and the axle bolt tightened.

With things loose, you tighten the axle bolt. Then the forks settle in where they want to be. After that, you can tighten the pinch bolt and the fork brace.

[bryan88]

 Thanks. Thought you were talking about the bolts at the bottom of the forks, thought how the %#$@ does one do that!

[Kerry]

For "visual learners",  the spacer referred to is item 6 in this diagram:




and the pinch bolt is item 16 in this diagram:




EDIT: For details on the time that I caused a loud "TAT TAT TAT TAT" sound when the front wheel rotated (after messing with the forks, because I moved this spacer) see [THIS OLD POST].

[Janx101]

The axle goes through a spacer on the right fork. That spacer is held in place with a pinch bolt. That must be loose when you install the wheel and tighten the axle. after the wheel is on, then the floating spacer will be where it wants to be and you can tighten the pinch bolt.

actually, before that you tighten the fork brace. Fork brace should not be tightened until the wheel is in place and the axle bolt tightened.

With things loose, you tighten the axle bolt. Then the forks settle in where they want to be. After that, you can tighten the pinch bolt and the fork brace.

.... ahhhh .... hmmm .... noted now.... that explains why the pyramid seals i had put in originally started messing up almst straight away ... i think... 

i removed and re-installed the actual forks ... but a mate did the seals...

soon as i read this .. i had a mental flashback to the order i put it all back together ... not like this...

note to self... future reference!! 

[bryan88]

For "visual learners",  the spacer referred to is item 6 in this diagram:




and the pinch bolt is item 16 in this diagram:




EDIT: For details on the time that I caused a loud "TAT TAT TAT TAT" sound when the front wheel rotated (after messing with the forks, because I moved this spacer) see [THIS OLD POST].

I didn't know that was a spacer, assumed the axle was just machined that way. Though I suppose it does make more sense from a machining/costs point of view. Mine is probably seized onto the axle 

[GS Paul]

Great info from everyone!
Should I replace the dust covers while I'm at it? Or is the fork seal swap all o need to worry about?
Cheers.

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[codajastal]

Great info from everyone!
Should I replace the dust covers while I'm at it? Or is the fork seal swap all o need to worry about?
Cheers.

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Only need to change the dust covers if they have perished.

[GS Paul]

Thanks.
Also thanks Adidasguy on the re-assembly order! Great info

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[Snake2715]

I didn't check your location, but these i purchased in June. they were genuine K&L and included dust seals. if your there it may be easiest to do new seals. they came quick as well. cheapest I found em.

http://www.ebay.com/itm/SUZUKI-89-00-GS500-E-FORK-SEALS-WIPERS-/190869602200?pt=Motorcycles_Parts_Accessories&hash=item2c70b6ff98

[gsJack]

That eBay link above is for 89-00 GSE models so it probably fits all year E and F but not 01-02 GS I think.  When I bought seals for my 02 back in May 09 the Suzuki fiches showed 3 different seals for 89-00, 01-02, and 04 and later F models.  A more recent check showed all used same part number now except 01-02 which were still different from all the others.  OP above mentions 01 model GS.  If anyone knows for sure that the 89-00 and 04-09 common seal will fit the 01-02 models post up. I don't feel like digging into it again.   

[Snake2715]

Reading comprehension for the win! maybe he has a similar price on the correct seals? sorry about that OP.