1st, if there is a link someone can provide that has step by step instructions including tor. values on reassembling a pair of '95 GS500E forks I'd appreciate it.

If there isn't a link but you can give me instructions for "Dummies" I'd appreciate it, especially about how much oil to put in(cc).

I have them completely disassembled, and will be putting in new Dust Seals and Oil Seals and just want to have "Write Up" with me in case I get stuck.

I have the "Special" tool memntionoed here on the site, and used it to remove the dampening Rod thingy.

The below picture was taken before I removed the other seal, inner tube and the dampening unit(Using special tool)

So how does it all go back together, when do I put the oil in, how much> What size PVC pipe for getting the seals seated? Trq. value on the allen head bolt in bottom of the leg, ectera.



Thanks.

best advice i can give you is to put it back together the same way you took it apart.. Never had a problem with mine that way.  AS far as the oil i added it in right before i added the springs.. but its been awhile.  as far as the allen heads i never worried about torque specs and tighetend them down as hard as i could without stripping them.   i would have to track down my book to tell you the exact amount of oil if i can find it today ill post it for you but im sure someone on here has it memorized.

I believe the fork oil should be between 375mL to 382mL.  The proper way to measure your fork oil is from the top, I'm not sure what the distance is though.

Quote from: bucks1605 on May 18, 2008, 01:35:53 PM
I believe the fork oil should be between 375mL to 382mL.  The proper way to measure your fork oil is from the top, I'm not sure what the distance is though.

4.5 inches from the top,fork colapsed,and spring removed.

Im not out in the garage, but I'd like a actual volume to put in it, once I start putting parts back together, I don't want to have to mock up (Collapsed inards minus spring) fill with oiol, take out stuff put springs in/seals....

Yeah it's been a bit since I took them apart, actually one leg is still assembled, I might disassemble that leg and use it as a guide to assemble the other....

There's a good HOW TO in the FAQ section:

http://gstwins.com/gsboard/index.php?topic=25706.msg267120#msg267120


Also, this site has lots of pictures:

http://www.geocities.com/inline_four/team_smelly/diy/fork_seals/


Good luck!

Quote from: Fry on May 18, 2008, 03:26:21 PM
Im not out in the garage, but I'd like a actual volume to put in it, once I start putting parts back together, I don't want to have to mock up (Collapsed inards minus spring) fill with oiol, take out stuff put springs in/seals....

Yeah it's been a bit since I took them apart, actually one leg is still assembled, I might disassemble that leg and use it as a guide to assemble the other....

The way I stated above is from a Suzuki Service Manual I viewed at my local library.

My service manual quotes a figure of 382ml per leg.

Quote from: sledge on May 19, 2008, 02:43:48 AM
My service manual quotes a figure of 382ml per leg.

Is your manual a US or Euro?Euro's,I think,not sure,they may be different.