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Message started by Bubba on 04/16/15 at 09:22:16

Title: fork seal tool
Post by Bubba on 04/16/15 at 09:22:16

So I was getting off the bike and noticed that my left fork had a bunch of oil on the slider...
I suppose I can do the playing card trick to see if it's just gunk around the seal but was wondering if I have to remove the fork to do that?

Anyway, I know I can probably replace the seals myself but I'm not sure I want to since it seems like a pain...

What's the going rate for a shop to do the job (NOT a dealership!)?

Plus, I've read the tech section tutorials but the tool to use to break free the lower allen key is confusing...anyone have a picture of what they used?
Thx!

Title: Re: fork seal tool
Post by Dave on 04/16/15 at 09:24:27

Just make a little hook tool from a thin piece of plastic....a milk bottle or something similar will work.

https://www.youtube.com/watch?v=8wlzfoVroSY

Title: Re: fork seal tool
Post by justin_o_guy2 on 04/16/15 at 11:57:03

We had a lady from Hawaii. She made costumes and built sets for a theater group. She also rebuilt her forks. And a complete novice to bikes, IIRC.
AND yes, forks intimidate me, but, the people here could get me through.

ETA, not true today,, my heads not right, I'm selling guns and giving up my drivers license... And it was a 2day ordeal getting the.mower running.

Title: Re: fork seal tool
Post by Bubba on 04/16/15 at 12:12:28

thx...I know I can do it,,,just not sure I want to...seems like a lot of work if I can throw 100 bux at someone to do it...

I figure I'd spend probably 4 hours making a tool to release it, getting all my ducks in a row and taking my time and I'd still have to buy oil, seals and maybe bushings...

first off, I'm going to try the seal mate...worth a shot for 5 bux

Title: Re: fork seal tool
Post by Bubba on 04/17/15 at 09:54:37

So I made a homemade seal mate by cutting out some plastic from a cinnamon roll container...yummy!

Pumped the suspension to reseat the seals and it seems to have worked!

Won't know for sure until I can ride again (we got 8 inches of sloppy wet snow last night)

But back to the original question...does anyone have a picture of their homemade tool to release the damper rod?
If I do change the seals out I'd like to see what others have used...
Thx!

Title: Re: fork seal tool
Post by Dave on 04/17/15 at 10:24:19

I will take a photo this weekend of the tool I made.

A correct sized bolt with a 3/8" drive socket on the backside. You just use your 3/8" ratchet and a long extension (taped together so it doesn't come apart and drop into the fork tube).

Title: Re: fork seal tool
Post by Gary_in_NJ on 04/17/15 at 10:24:51

There are several options in this thread

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1298159607

To be clear, the tool doesn't "release" the damping rod, rather, it holds it while the M8 cap screw on the bottom side is loosened and removed.

If you need a seal driver tool, that can be made from a 2" length of 1-1/2" PVC and a 1" length of 2" PVC (both "slit" up the side) and a hose clamp. The PVC tool is clamped to the upper fork tube and the tube is then used as a driver. $2 tool...lifetime of enjoyment.

Title: Re: fork seal tool
Post by Bubba on 04/17/15 at 11:20:31

Awesome!
Thanks everyone!

Title: Re: fork seal tool
Post by Dave on 04/23/15 at 13:57:26

OK...here is the photo of what I built.

Damaged 3/8" drive flex joint welded to a bolt. The head is 15/16" inch, so I suppose a 24mm hex would work as well. You just need a long 3/8" drive to make it work....you use this to hold the damper rod in place while you loosen the allen head bolt at the bottom of the forks.

Title: Re: fork seal tool
Post by Gary_in_NJ on 04/23/15 at 15:59:11

And if welding isn't your thing, there are other ways of making this tool:

- Threaed rod with two nuts loctite'ed into position
- Two bolts joined with a union

I'm sure there are others that I haven't thought of, but it needn't be a fancy tool.

Title: Re: fork seal tool
Post by russ on 06/28/15 at 09:45:06

thanks. made tool of 5/8" diam bolt and 1/2"black iron pipe. made a booger weld and went for it. job went great. thanks again

Title: Re: fork seal tool
Post by justin_o_guy2 on 06/28/15 at 15:01:38

booger weld

I had a desk in school I'm pretty sure was held together exactly that way.