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Thread: Front Fork Tutorial?

  1. #1
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    Default Front Fork Tutorial?

    I was wondering if someone has created a step-by-step guide on rebuilding the front forks on the GS's. I've never done it and mine needs it done.
    Current Bikes:

    2019 Indian Chieftain Classic
    1981 Suzuki GS750E

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    2006 Suzuki C50

  2. #2
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    Quote Originally Posted by nutz4spd View Post
    I was wondering if someone has created a step-by-step guide on rebuilding the front forks on the GS's. I've never done it and mine needs it done.
    Front Forks? Are there rear forks that I don't know about???
    I'm just razzin ya. I imagine most people on here would point you in the direction of your shop manual.
    I can relate though, I love a good tutorial. Have you checked Youtube? I just did a search, "how to rebuild GS motorcycle forks", and found a bunch of vids related to the subject.
    Last edited by RustyTank; 02-02-2021 at 03:04 PM.
    1979 GS850G, currently being rebuilt from the frame up. We shall see how that go's

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  3. #3
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    If you find the factory service manual (available for download from BikeCliff's Website, linked in my signature) insufficient, you can take a look at this supplement. It may apply to your bike, not exactly sure. When I rebuilt mine, I used both as my guide, along with my Clymer's manual, and asked for advice on the forum if I got really stuck on something.

    Before you ask. OEM fork seals only, and 10W Fork Oil is fine for most people.

  4. #4
    salty_monk's Avatar
    salty_monk is offline Forum LongTimer GSResource Superstar
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    You can usually just get away with new oil seals & switching out the oil... of course better springs from Sonic or Progressive help a lot. Emulators too if you're going for the full upgrade...

    From memory oil height should be about 140mm when refilling.

    1980 GS1000G - Sold
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  5. #5
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    OPINION WARNING ***

    Buy the Motion Pro seal driver is the best advice I can give you -
    I have done forks on several bikes now and this one thing has saved me from re-doing them -
    It is not easy for a novice to get a good seal by using PVC or something else to drive and seat the new seals

    Do research - Check You Tube - many forks share common parts and designs so you may learn something that could help once you get going.
    Currently in the Stable :
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    1983 Suzuki GS850 GL Blue & Black

    " I am never lost until I run out of fuel...until that moment I am EXPLORING."
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  6. #6
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    Last edited by dorkburger; 02-10-2021 at 03:31 PM.

    When consulting the magic 8 ball for advice, one must first ask it "will your answers be accurate?"

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  7. #7
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    Hi, one thing not mentioned in the manual is that it is usually easier to crack loose the fork cap and damper rod bolt when the forks are still on the bike with weight on the front wheel . Just don't use forget to loosen the fork top triple clamp bolts before you crack the fork cap. I have also use old fork seals with small section cut out [about 2mm] so as to reduce the O.D, to drive in the new seals.
    1983 gs1100ed restro-mod. 1998 gsxr 1100 almost mint, 2001 honda cr250 woods weapon, 2019 kawasaki klx250, 2011 Beta 250 evo trials bike, 2017 Montesa 300rr trials bike

  8. #8
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    https://www.motionpro.com/c/ringer-fork-seal-drivers

    Not sure which size your bike needs --

    I own 2 sets -- one for my GS850GL and one for my GL1800 Goldwing -

    Best money I ever spent
    Currently in the Stable :
    2002 Honda Goldwing GL1800 Sunburst Pearl Orange
    1983 Suzuki GS850 GL Blue & Black

    " I am never lost until I run out of fuel...until that moment I am EXPLORING."
    - Carl R. Munkwitz

    Munk's Maxim: "There is no such thing as a cheap motorcycle"

  9. #9
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    cowboyup3371 is offline Forum LongTimer Past Site Supporter
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    Quote Originally Posted by chris View Post
    Hi, one thing not mentioned in the manual is that it is usually easier to crack loose the fork cap and damper rod bolt when the forks are still on the bike with weight on the front wheel . Just don't use forget to loosen the fork top triple clamp bolts before you crack the fork cap. I have also use old fork seals with small section cut out [about 2mm] so as to reduce the O.D, to drive in the new seals.
    Or you can put it in a bench vise with the spring still in and top on then open it up. Also a powered impact driver will make short work of it

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  10. #10
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    Have a look here for fork strip info
    http://members.dslextreme.com/users/...nt_GS850GT.pdf
    The big guy up there rides a Suzuki (this I know)
    1981 gs850gx

    1999 RF900
    past bikes. RF900
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