Can anyone help?
I have a 1991 GS500E and found a set of 2001 GS500 fork leg assemblies to buy.
Will these fit right onto my bike? They'll fit the stock triple clamps? And the stock 91 brake caliper will bolt right on?
Does anyone know for SURE if these are compatible? I need to be POSITIVE.
Thanks!
Hmmm. The best I could think of was to compare part numbers at BikeBandit (http://www.bikebandit.com) for the two years. Judging from what I see there, I've got good news and bad news.
The good news is that many of the internal parts listed for the 1991 fork assemblies (http://houseofmotorcycles.bikebandit.com/partsbandit/oem_schematic_view.asp?schem_dept_id=723958&section_dept_id=1&section_dept_name=OEM+Parts&dept_type_id=2&model_dept_year=1991&model_dept_mfr=Suzuki&model_dept_id=703248&model_dept_name=GS500EM) match up with those for the 2001 fork assemblies (http://houseofmotorcycles.bikebandit.com/partsbandit/oem_schematic_view.asp?schem_dept_id=715203&section_dept_id=1&section_dept_name=OEM+%28Stock+Parts%29&dept_type_id=2&model_dept_year=2001&model_dept_mfr=Suzuki&model_dept_id=703275&model_dept_name=GS500K1).
The bad news is that the part numbers for the outer tubes, and for the complete fork assemblies, are different. :x
I know that the front brake caliper changed in 1996, but when I asked someone said that the new and old calipers are bolt-on replacements. The fact that the part numbers for the 1996 fork assemblies (http://houseofmotorcycles.bikebandit.com/partsbandit/oem_schematic_view.asp?schem_dept_id=723963&section_dept_id=1&section_dept_name=OEM+%28Stock+Parts%29&dept_type_id=2&model_dept_year=1996&model_dept_mfr=Suzuki&model_dept_id=703270&model_dept_name=GS500ET) are identical to the 1991 numbers seems to bear this out.
I thought I remembered someone saying that the front calipers changed again in 2001. If you compare the 1996 front caliper (http://houseofmotorcycles.bikebandit.com/partsbandit/oem_schematic_view.asp?schem_dept_id=717828&section_dept_id=1&section_dept_name=OEM+%28Stock+Parts%29&dept_type_id=2&model_dept_year=1996&model_dept_mfr=Suzuki&model_dept_id=703270&model_dept_name=GS500ET) part numbers with those for the 2001 front caliper (http://houseofmotorcycles.bikebandit.com/partsbandit/oem_schematic_view.asp?schem_dept_id=717821&section_dept_id=1&section_dept_name=OEM+%28Stock+Parts%29&dept_type_id=2&model_dept_year=2001&model_dept_mfr=Suzuki&model_dept_id=703275&model_dept_name=GS500K1), you'll see that they're identical except for the pads and a shim that was added in 2001. On top of that, the part numbers for the brake rotor itself vary from 1991 (http://houseofmotorcycles.bikebandit.com/partsbandit/oem_schematic_view.asp?schem_dept_id=724939&section_dept_id=1&section_dept_name=OEM+Parts&dept_type_id=2&model_dept_year=1991&model_dept_mfr=Suzuki&model_dept_id=703248&model_dept_name=GS500EM) to 1996 (http://houseofmotorcycles.bikebandit.com/partsbandit/oem_schematic_view.asp?schem_dept_id=725205&section_dept_id=1&section_dept_name=OEM+%28Stock+Parts%29&dept_type_id=2&model_dept_year=1996&model_dept_mfr=Suzuki&model_dept_id=703270&model_dept_name=GS500ET) to 2001 (http://houseofmotorcycles.bikebandit.com/partsbandit/oem_schematic_view.asp?schem_dept_id=724190&section_dept_id=1&section_dept_name=OEM+%28Stock+Parts%29&dept_type_id=2&model_dept_year=2001&model_dept_mfr=Suzuki&model_dept_id=703275&model_dept_name=GS500K1).
Dizzy yet? :o So am I!
Bottom line - if you have to be "POSITIVE" then I would say pass it up. But it's so close you can taste it; what if everything would work just fine? Aaargh!
Hi Kerry,
I went to BikeBandit.com (thanks for the tip, I had never seen that site before) and compared the most critical parts, as you mentioned, between the 1991 and 2001 models.
The parts I really need are the inner fork tubes, which as you said are the exact same part numbers. (Thanks for confirming that!)
The other smaller parts do appear to be the same also, so that is nice. The fork lowers (outer tubes that carry the wheel and caliper) do have different numbers, as you said, but my hunch is that it's because they added those small rubber fork protector pieces at the top of the lower legs. I'm hoping the caliper mounts are the same because I'd like to just bolt them right on.
If those parts are changed, though, I'll have a bigger than desired job to replace to inner tubes on my existing forks, but those parts will at least fit, thanks to your help in checking part numbers. THANKS for that info!
:)
I hope I can offer you some help in exchange some time!
The biggest clue here is your steering head bearing part numbers, I have found that amoung its smaller bike line Suzuki uses the same bearings for quite a few bikes. It makes since because it keeps the price down.
Infact they use a bearing that they have been using from the 70s thru some bikes till now, However I have not checked on the GS500.
One thing you want to watch however is fork spacing and fork size, this will let you know if you need complete front end including headlight etc as they will need to be able to fit on the front end of choice.
Funny I seem to recall that early Gsxr front ends have these same bearings and thay give you a lot of more fork tuning ability.
after fitting a different set of forks you will need to set up the weight bias of the bike to make it not have any weird handleing problems and then go for it
Jim
Hi all,
Just some helpful info I have learned:
I bought a set of 2001 GS500E fork leg assemblies to replace the stock legs (a scratched inner tube) on my 1991 GS500E. Because there are different part numbers for the lower leg and the caliper, there was no guarantee that they would just bolt on. But since the inner tubes and all the other small parts (seals, damper rods, anti-friction rings, etc.) share the same part numbers, I was hopeful.
Here's the result:
The only reason the lower legs have a different part number from 1991 to 2001 is that the 2001 legs have a groove at the top for new rubber inner tube protectors that Suzuki added to the bike. All other tolerances are the same, including mounting points for the caliper and axle. And the brake caliper is different and uses different pads, but the mounting points are exactly the same. So it was a simple bolt-on process, rather than having to take apart one of the legs to scrounge out a new tube. A lovely spring day working on the GS -- perfect. :)
I just thought this info would be helpful for anyone else replacing parts as I did.
Best wishes,
Todd