Failed Mot on fork seals even though I just fitted them, read somewhere that the end bushes might need replaced...?
2. Getting a koso speedometer so do I just chop old speedometer cable as no longer needed or is there a way to take it off without having to custom a bush for front wheel?
3. As for Rev cable, will I need to plug up where it goes in engine to prevent oil leak when I take it off?
Thanks in advance
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Sorry about those fork seals.
You can disassemble the cable assembly at the front wheel, no need to chop anything or make custom bushes.
You need to plug the tach hole or else you will have a major oil leak, if that wasn't bad enough you'll be sucking road debris directly into the valve train. The thread is the same size as an O2 sensor and oil pan drain plug threads (M18 x 1.5) so this is what I used to plug mine:
https://www.amazon.com/gp/product/B009PQ617Q/ref=oh_aui_search_detailpage?ie=UTF8&psc=1
At first I bought a plug that had a hex head on it but there is not enough space for that. You need a plug with a lower profile head like the one I linked.
Did you use genuine Suzuki OEM fork seals or aftermarket ones?
Thanks for info guy, I'll be ordering that bolt soon, as for fork seals, I'm not sure what ones I used, are the oem ones the way forward?
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I've had mixed results from some aftermarket seals, namely 'Pyramid Parts' seals. Pretty annoying doing that job only to find that the brand new aftermarket seals leak! OEM don't cost THAT much more so I'd go for original to be sure.
I used All Balls Racing seals and bushes. Had them recommended and they seem pretty good so far. They don't make wiper seals for some reason.
I made spacers for the front including a replacement for the speedo as I am putting an Acewell electronic speedo on. Lighter and should stiffen the front axle a bit as well that should help the bushes and seals last a bit longer.
(http://i130.photobucket.com/albums/p248/gregjet/GS500F/front%20wheel%20spacers%201_2.jpg) (http://s130.photobucket.com/user/gregjet/media/GS500F/front%20wheel%20spacers%201_2.jpg.html)
Originals:
(http://i130.photobucket.com/albums/p248/gregjet/GS500F/front%20wheel%20spacers%202_2.jpg) (http://s130.photobucket.com/user/gregjet/media/GS500F/front%20wheel%20spacers%202_2.jpg.html)
Nice one, I wouldn't know where to start with all that machine work or who to see lol
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Most local machine shops can do there easily. Just make sure you stress that the lengths are critical as they determine to side load on the wheel bearings. A single replacement shouldn't be extremely expensive in Al.