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Removing fork seals is a pain in the A**!!!

  • Thread starter Thread starter GS750cafe
  • Start date Start date
G

GS750cafe

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I've tried a screw driver, a chisel (to pry like a screw driver) with pipe for leverage and now heating them with a torch... still stuck and now the outer tube is discolored! WTF! I'm trying not to buy the seal removal tool. It doesn't look like it'll be any better than what I've got, but I may have to. This afternoon project has turned into days...:(

Anybody got any other suggestions?
And, why are they so stuck???
 
FIRST thing....do you have a FACTORY Suzuki shop manual? If not, that is your first thing to fix!!! After that, it is self explanatory. Ray.
 
There a lot of youtube vids on the process
as RR said do dload the manual from the basscliff site.
 
Did you take the circlip that holds the seal in out? They're pretty tough to get out if you don't do that. ;).
 
rapidray said:
FIRST thing....do you have a FACTORY Suzuki shop manual? If not, that is your first thing to fix!!! After that, it is self explanatory. Ray.
Click to expand...

I will never understand why anyone would ever try to work on an old bike (or car, or boat, or airplane) without the specific shop manual to use as a guide. There is nothing difficult at all on these bikes, as long as you know what process to use.

Without a mnanual, you might as well just use a hammer and some TNT on it.
 
Wow, lot of support this time.
Yes I have a manual, but it's the Clymer
Yes I removed the allen bolt and separated the upper tube and lower fork.
Yes I removed the circlip.
I guess I'll download the FACTORY Suzuki manual before I get out the hammer and penolite!
 
Sounds like you have it all apart right? Drill a small hole in the metal part of the seal. Thread a long screw into the seal and lever it out with a hammer or pry bar. put a piece of wood over the fork to protect it..
 
Usually they are not that bad.My Honda project bike has the exception.Not out yet.:evil:
 
Drill a small hole in the metal part of the seal. Thread a screw into the seal and lever it out with a hammer or pry bar
Click to expand...

Might have to try that. Sounds a little touchy though... one slip with that drill bit!

The FACTORY Suzuki manual says "replace oil seals found in damaged condition"...
well they are pretty damaged now!!!
 
Seal puller at autozone or harbor freight may be $10. They're handy to have when all your buddies want you to do their forks :)

Just be mindful you don't nick up the seal seat or anything.
 
Hi,

There are TWO fork seal replacement guides on my little website. Have a look to see if they might help.


Thank you for your indulgence,

BassCliff
 
Thanks guys. I'm gonna spend some time on it today. I checked your guides BassCliff; thanks for compiling so much info in such an easy to read format! Very helpful - a lot more helpful than "read the manual"!

The bike is a '77.

I'll see what I get accomplished today. :)
 
I had really good luck with the air pressure method. I used one of those cheap 12v "250psi" compressors.
Just pumped them up and waited.
Pop!, Pop!
 
Got it! One at least.

I used a combination of torch and prying with chisel/pipe extension. Cleaned everything up and now reassembling. Thanks for everyone's help. Seems like it is just one of those things that can be a PITA!

FWIW - my forks don't have air valves, so that wasn't an option.
 
i used the pull and slam method.
which is to get one person to hold the main body of the Fork, and the other person grabs the inner tube and just starts yankin and slammin until the seal pops out.
(obviously you push the tube IN fully between Yanks)


Do those forks actually HAVE air nozzles?
I can't find them on my 78....
 
1_v8_merc said:
i used the pull and slam method.
which is to get one person to hold the main body of the Fork, and the other person grabs the inner tube and just starts yankin and slammin until the seal pops out.
(obviously you push the tube IN fully between Yanks)


Do those forks actually HAVE air nozzles?
I can't find them on my 78....
Click to expand...


Worked great for me too !
 
Do you have a shaft seal puller? Basically looks like a long handle with 2 different hook shapes on each side. Makes life a ton easier, and you can always add a pipe or something if you need more leverage.
 
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