Anyone replaced their fork seals on an F model???  The Suzuki manual shows a special tool (looks like an socket extension w/ a T handle) for removing the allen bolt/nut inside the fork tube.  I found the following post from Kerry in the FAQ section, but the link isn't working...and I think that's for the pre 04 models anyway...

Also, the book mentions a fork seal installation tool that runs about $80.  Is this really needed???

QuoteAdditional info that might help someone out there:
* See this thread for two different versions of a home-made tool that helps you to loosen / retighten the damper bolt at the bottom of the forks.

* Here's a picture showing the size of PVC pipe that works to seat the new fork seal (1 1/2", Schedule 40).  It doubles as storage for the above-mentioned tool.

Hope you guys can help, my cylinder head should be back later this week and I want to have everything else ready so I can just finish putting the engine back together and go!!!  I'm sick of not being able to ride!!!!!!!!!!!!!

yea... I'm having the stealership replace mine.


its free that way.

Quote from: TragicImage on September 12, 2006, 02:20:20 PM
yea... I'm having the stealership replace mine.


its free that way.

How so?

As far as I know there is no change in the forks from the E to F models. Don't buy the expensive tools. I just used the ones you linked to and it worked perfectly. Just go to your local Lowes or Home Depot or whatever. It will only cost about $10-$15. I used 2 5/8" bolts. I think 9" long. Use a connector to join the two with epoxy to hold them together. If you had access to ~18 of allthread rod and some nuts to weld on you could probably do it even cheaper. A couple feet of 1 1/2" schedule 40 pvc pipe to drive the seals and you're set. I'm a total noob when it comes to working on bikes and I didn't have any problems.

Quote from: flyingbeagle71 on September 12, 2006, 01:49:46 PM
Anyone replaced their fork seals on an F model???  The Suzuki manual shows a special tool (looks like an socket extension w/ a T handle) for removing the allen bolt/nut inside the fork tube.  I found the following post from Kerry in the FAQ section, but the link isn't working...and I think that's for the pre 04 models anyway...

Quote from: annguyen1981 on September 12, 2006, 02:23:05 PM

Quote from: TragicImage on September 12, 2006, 02:20:20 PM
yea... I'm having the stealership replace mine.


its free that way.

How so?

fork seal started leaking at 6.5k miles... 5 months after I bought the bike.......

humm better than me my 04 blew one out after coming down over the top of a hill.
20k on them  so i guess they lased long enough

Quote from: SeriousGeorge on September 12, 2006, 02:45:35 PM
As far as I know there is no change in the forks from the E to F models. Don't buy the expensive tools. I just used the ones you linked to and it worked perfectly. Just go to your local Lowes or Home Depot or whatever. It will only cost about $10-$15. I used 2 5/8" bolts. I think 9" long. Use a connector to join the two with epoxy to hold them together. If you had access to ~18 of allthread rod and some nuts to weld on you could probably do it even cheaper. A couple feet of 1 1/2" schedule 40 pvc pipe to drive the seals and you're set. I'm a total noob when it comes to working on bikes and I didn't have any problems.

Thanks for the instructions on building the tool.  Still not sure it will work with the F models, the front forks are one of the things that did change on the F.  Well, maybe they didn't change, but they are in a different section in the repair manual.

E Model Front Forks:



F Model Front Forks:



The tool needed is shown in this picture called "T" handle and Attachment "A"...

Anybody know what the top of the Damper Bolt in the 04 shock looks like?  The manual's picture makes it kinda look like a torix head on it...