Fork Seals (first time)

[neilbags]

I've been preparing to replace fork seals on my '12 GS500F - never done this before and it's my first bike. I've read all the posts about using a broomstick to compress the damper spring, buying special tools, undo-ing the damper rod bolt before disassembly etc.

But ... I just met an old motorbike mechanic who knows Suzukis, and he told me instead to just carefully drill a small hole in the old seal, screw in a small wood screw, and lever the old seal out using a pair of side cutters. This seems way easier. Will this work? Is this a bad idea? Has anyone else successfully done it this way?

[Rallyfan]

Are you sure the seals are shot? On mine, I managed to stop the leak by cutting a piece of 35mm camera film into a "J" shape and running it across the surface of the fork under the seal, so that I could "shovel" grime out that had been caught between the seal and the fork. That was about 5 years ago. So far, so good. Worth a try.

[Bluesmudge]

Sounds like that method would work. And if it doesn't work, you are replacing the seals anyways so it doesn't matter that it will ruin them. If you try it and it does work, please report back!

I've done the broomstick method. Its pretty finicky on the new style forks with the smooth damper rod top.  If I had to do it again I would try an impact driver on the damper rod bolt before disassembly. I've had that work on other motorcycle forks of similar design and it was much easier.

[mr72]

Impact driver would be preferable if it works. You still need the "special tool" to put it back together though. ISTR Kerry on this forum (or someone else...) posted a how-to make your own special tool. I made one from allthread with the correct size nut on both ends and JB weld on the threads keeping them from turning. Worked great. Had to do the job twice. Still leaks, but my tool works.

[neilbags]

I made one from allthread with the correct size nut on both ends and JB weld on the threads keeping them from turning.

What year model did you do this on? From what I have read this won't work on late models ('05 or '06' onwards)

[neilbags]

Are you sure the seals are shot?

No I'm not. I will try this and see if it still leaks. Thanks for the tip!

[mr72]

I made one from allthread with the correct size nut on both ends and JB weld on the threads keeping them from turning.

What year model did you do this on? From what I have read this won't work on late models ('05 or '06' onwards)

you may be right. Mines a '92.

[Bluesmudge]

Correct, the all-thread/bolt method only works on the older style forks that have a star pattern on top of the damper rod for the bolt to bite in to. The newer forks are smooth on top so there is nothing to grip.