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GS1000 fork seals

  • Thread starter Thread starter BADJACKSON
  • Start date Start date
B

BADJACKSON

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So, I have a pretty bad leak coming out of the top of my L fork. I read through my service manual & it lists several "special" tools. I searched fork seals on here & found that I could make the only special tool I really need. Correct? Also, what do I order??? Fork seals, & dust boots? Maybe new springs if I can afford them? What about all the rubber grommets mounted on the forks? I read that I probably won't need the bushings that are down inside the forks (my 78 has less than 18K miles on it). So, please give me the run down. Thanks.
 
Get the fork seals. If your dust boots are not cracked, re-use them.

Lift the dust boots, look at the retaining mechanism for the seals. If it's pretty rusty and corroded, get whatever is in there. Some bikes have a large circlip, others have a wavy wire. Stiill others have a wire that hides quite well in a groove, and will drive you mad trying to find it, if you don't know what you are looking for.

Make the tool. If you have access to an air wrench, use it.

If you skip replacing springs because you "can't afford them", maybe owning a 35+ year-old bike is not for you. New Progressive (brand) springs are about $85 from Z1. Sonic springs are about the same price from Sonic Springs. We have Progressives in a few of our bikes, I just put Sonics in my 850 and can not believe it is the same bike. It rides SO much better than before, I like the ride quality better on my 850 than on my Wing.
eek.gif

You really can't afford to NOT replace the suspension, as that is what keeps the wheels on the road. It's not just comfort, it's a SAFETY issue.

Get some fork oil for when you put it all back together. 10w will probably work best. Some insist on using 15w or even 20w, but I have found them to be too harsh and uncomfortable.

.
 
Steve, thanks for the tips! It's not really a matter of can't afford, it's just that I've sunk quite a bit into her in the last 2 weeks, and she still isn't road worthy! I did the research on the Sonic Springs, $85 isn't bad. Dust boots are shot. So, I'll get boots & seals & springs.
Thanks!
 
Make a fork drive rod tool from some electrical conduit. And as for the dust seals. I would add that if they arent also SUPPLE enough to actually wipe the stations replaces them.. just cuzn they arent cracked doesnt mean they are actually wiping much.

I lock the handle in the vice, slide the lower on and get the nut head locked in and then remove the allen head bolt. The head on the bolt measures 19MM.

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Last edited:
If you have a 5/8th spark plug socket and enough extensions this has worked for me:
 
Or two nuts locked together on a piece of all thread works too.... In a push a broomstick works if you get an impact on the other side. :)
 
Do the fork lowers need to be separated from the tubes in order to change the springs? I didn't see that in the tutorial on Basscliffs website.
 
If you have the air valves on the tops of the fork tubes you can pop the retaining clip on the fork seals & pressurise them until the seal pops out. I've done that a couple of times where I know the fork internals are in good shape & don't want to split them. I think it took about 85 PSI but I was able to do it with a bicycle "track" pump easily enough.
 
I did the same thing but with an air compressor. It took a little while but it worked. Oh, and make sure you drain the tubes COMPETETLY or things get a little messy when the seals finally pop.
 
Use an impact BEFORE you take the springs out. Spring tension will keep the damper rods inside from turning. Usually.
 
Great advice here, looking forward to diving into this project myself this weekend. Question, does just the centerstand and leaning the bike back get it up high enough to pull the forks out?
 
No, you need to tie it down in back, set something heavy on the seat, or put a block or jack or something under the front of the engine or frame. The front is heavier, at least until you get the wheel off. If it tips forward, the center stand folds up, the whole thing tips over. Ask me how I know this.
 
Many thanks for this thread, I haven't been able to ride because I have bad fork seals, finally getting around to changing them, springs and seals arrive this weekend. Hopefully back on the road soon.
 
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