Installing new fork seals and PS springs

[Anonymous]

I bought some 15 wt. fork oil when I got the seals. No one has the bushings and they don't know if they can get them. I'm going to hunt some more today.

I keep reading this stuff about bushings, I don’t think my 1978 GS 1000 has bushings, at least they don’t mention any in my manual, am I correct? What do they do?

Roman.

[Billy Ricks]

They are teflon coated bushings used to minimize wear on the mating surfaces of the upper and lower tubes as the fork slides.

[Bert Patterson]

Thanks, Billy, and the rest. I'll let you know how it goes.

I know how you feel, Bert, since I was in the same position last summer with my 1983 GS750ES.....had it done by the dealer on 2 previous occasions. I changed the seals, both sets of bushings (inner and outer), fork oil and dust covers, plus installed PS springs and spacers. The job is not mechanically difficult, you just need to give yourself time to work methodically. Billy and others on this site gave me some helpful tips, also.

Best of luck,

Simon[/quote]

Thanks, Simon. I wish I had the bushings - other friends have repeatedly done it without changing them, but my shop manual says to and, more importantly, Mister Ricks says to. It would take me too long to get them, I don't want the bike sitting in the shop and since the leak is down to almost nothing, I assume I've about run out of fork oil.

I've had bikes for 33-34 (?) years, but I've never done this. Bureaucrat (okay, and a lawyer) and a pretty good carpenter, but I've passed on most mechanically efforts. It's time to learn something, I guess.

I've got new PS rear shocks to install, but the front may be all I can handle in one day.

[Billy Ricks]

Bert,
When you get things apart take a good look at the bushings. If it looks as if the teflon is in good shape and not worn through or scratched up then you can probably reuse them with no ill consequences.

[Bert Patterson]

Bert,
When you get things apart take a good look at the bushings. If it looks as if the teflon is in good shape and not worn through or scratched up then you can probably reuse them with no ill consequences.

Cool. Thanks for all your help, man. I almost think I can do this.

[Anonymous]

Bert,
When you get things apart take a good look at the bushings. If it looks as if the teflon is in good shape and not worn through or scratched up then you can probably reuse them with no ill consequences.

Cool. Thanks for all your help, man. I almost think I can do this.

Bert, as Billy says, the bushings are teflon-coated metal items that help the inner and outer fork legs slide past each other. My manual says the lower, inner one (installed at the bottom of the inner, chromed leg) should be replaced at the same time as the seals. Interestingly, this bushing was in great shape on my bike, perhaps because it had been replaced when the seals were previously done by the dealership. However, the upper, outer bushing (installed near the top of the outer fork leg near the seals) showed clear signs of wear on my bike.....changing this bushing is not mentioned in my manual, so perhaps this was the original bushing from when the bike was new. Fortunately, I had both sets of bushings, which are a snap to install while you have the forks apart. I got my bushings from a local bike shop, who in turn got them from a Suziki dealership. I do remember that it took a while for all the parts (seals, bushings, dust covers, PS springs) to arrive.

Don't worry about being a lawyer.......compared to the law, motorcycle forks are simple.

BTW, I did write up a "procedures" MSWord document on changing the seals for my future reference. If you would like me to e-mail you a copy, send me a PM with your e-mail address.

[Bert Patterson]

BTW, I did write up a "procedures" MSWord document on changing the seals for my future reference. If you would like me to e-mail you a copy, send me a PM with your e-mail address.

I will. Thanks, Simon.

[Billy Ricks]

I think the increased wear on the upper bushing is just because of it being located near the center of the fork and is subject to more pressure. I'll have a look around and see if I saved my old ones in case yours are shot Bert. They might be the same size as yours and were only used about 5 or 6 years before being replaced. I can't guarantee I still have them or can find them. If I do run across them and you need them you are welcome to them. They fit inside the upper portion of the lower leg.

[Bert Patterson]

I think the increases wear on the upper bushing is just because of it being located near the center of the fork and is subject to more pressure. I'll have a look around and see if I saved my old ones in case yours are shot Bert. They might be the same size as yours and were only used about 5 or 6 years before being replaced. I can't guarantee I still have them or can find them. If I do run across them and you need them you are welcome to them. They fit inside the upper portion of the lower leg.

Thanks a lot - I'll let you know. I took tomorrow off work for a proper four-day weekend, the sun's supposed to be shining so I'll be working outdoors. Starting early in the morning nearly guarantees there will be no beer involved.

Have a great weekend.

[Anonymous]

BTW, I did write up a "procedures" MSWord document on changing the seals for my future reference. If you would like me to e-mail you a copy, send me a PM with your e-mail address.

I will. Thanks, Simon.

Bert, I have e-mailed same to you about 4:15pm RMT. Let me know if it doesn't arrive OK.

P.S. It's good to have Billy around....he gave me the confidence to tackle my fork seals.....so far so good after 1500 miles.....of course, I'll bug him for a "refund" if problems occur in the future. :roll:

[Anonymous]

The bushing are still available (through RonAyers).
Looks like part numbers 51121-49500 ($7.12) and 51167-49500 ($4.99).
The fiche isn't completely clear so I'd double check the part numbers.

[jimcor]

Bert, I checked and the 11-1106 was used with the 1100G model so I can't help you out with a definite yes or no on requiring a spacer. It's amazing how many bikes use the same Progressive springs as my 550. BTW you aren't the only one playing motorsickle mechanic this weekend. Much rather be ridin'...but, like they say, "ya wanna play? ya gotta pay!

[Anonymous]

They are teflon coated bushings used to minimize wear on the mating surfaces of the upper and lower tubes as the fork slides.

Billy,

Is it possible that my old GS 1000 doesn’t have bushings; the manual doesn’t mention them at all.

Roman.

[Billy Ricks]

I guess it's possible, check bikebandit's diagrams.

[Billy Ricks]

I checked the diagrams for '80 and '81 1000s and didn't see any bushings. Seems they relied on castings in the lower legs, the seals, and a piston ring on the dampers to ride on each other. The bushings help to keep from wearing out non-replaceable parts. That's probably why many of you feel you get better damping with heavier oil. As parts hone themselves the tolerances get larger.