Fork Dismantling Tool

[KiwiCol]

Can someone please give me directions for making a fork disassembly tool for a K6.  I've read it's a 1" pipe with slots cut in with a grinder (Thx hooli) but how long does the pipe need to be?  How wide do the slots need to be cut? How deep do the slots need to be? What sort of wall thickness of the pipe? Any pic's of said item?

Took the black for a burst today, found oil coming out the top past the dust seal, say the seal is shot.  Anyone remember the Kawasaki seal number?  Recall it was the same part but way cheaper.

Thx guys.

[grog]

Kiwi, do you have bike suspension bloke near you? Now is chance to get them upgraded, springs etc. well worth the bucks, makes a big diff. A real big diff. Youll be amazed, i was.

[seth]

http://gsx1400owners.org/forum_test/index.php?topic=378.msg3079#msg3079

the pipe with the cross cut in to the end is for the earlier models you'll find details for both on this thread .
mine and vici's both .

[KiwiCol]

No unfortunately. I did go to see a bloke who was supposed to be good, spent about 2 hours talking to me about the forks, but never did anything, was going to find out stuff on 14 forks & get back to me, months later I went back, he looked up his dairy, found the entry & recalled it. said he'd get onto it & call me, never did.
So, No, there's nothing in Christchurch that I can find.  There's places in Akl, but they're out of the question. Like living in Syd or Mel & finding a place in Cairns that'll do the work - not going to happen aye.

And, it's for the black, so no rush. Liked riding it as a naked today too. Thinking along the lines of having the black as a hooligan / track bike & the blue as a more sedate tourer.  Take the 17 front off the blue & bung it on the black, put some new bars on it & fix the fork oil leak, get it re-complied & have both.    Just thinking, as I did like the ride today without the front fairing n all the other bits.

[seth]

@gsxbarmy  might be able to help with the forkseal part numbers i can't find it .
i do remember that suzuki did drop the price of std seals so there was hardly any price difference here in the uk .


this thread has a step by step for changing the seals

http://gsx1400owners.org/forum_test/index.php?topic=220.0

[KiwiCol]

Thx Seth, yeah read it.  That's how I know I need that tool to hold it inside.  I do have an air impact gun though, maybe I'd get away with it?  Might be worth a try. Doing it up might be a different story without any way to hold it still.  Air gun would probably over tighten it.

I'll get onto local agent here & find prices for bars & fork seals.   I looked at Renthal bars, $77 but $135 in shipping!! nuts.  OEM here (I think) are only $150. 

[seth]

i dont use an air gun but you should be able to strip it down with out the tools if you have one all the holding tool does is holds the cartridge while you undo the bolt from the bottom an air gun should spin the bolt fast enough that the cartridge comes lose without holding it and same when tightening on the refitting just stop as soon as its tight don't go mad and you'll be ok .

[KiwiCol]

Ok, Thx.  I'll have a crack at that then. 

[seth]

just go easy and you'll be fine the other trick is to wedge some bits of wood down the sides of the cartridge to help stop it spinning .
remember to check your fork stantions when apart for wear and any sharp edges/missing chrome that has caused the seal to fail in the first place .

[KiwiCol]

It never leaked before, I'd say it has something to do with going over that bank & into the trees.

[seth]

then while apart check it's not bent roll on a piece of plate glass or a known flat surface to see
I'm sure it'll be ok and just the shock of the sudden compression made it leak  but as its apart worth checking

[gsxbarmy]

@gsxbarmy  might be able to help with the forkseal part numbers i can't find it .
i do remember that suzuki did drop the price of std seals so there was hardly any price difference here in the uk .


this thread has a step by step for changing the seals

http://gsx1400owners.org/forum_test/index.php?topic=220.0

Fork Oil Seal: 51153-42F00
Fork Dust Deal: 51173-42F00

@seth @KiwiCol

[Andre]

Those originals would set me back by 90€ but can get them for 25€ from All Balls (56-150) (both include S&H)

While you have it apart you may want/need to do more. All Balls (38-6087) repair kit (does not contain the seals and dust cap) would cost 30€.

[Andre]

I just saw that you Brits can get the seals and dust rings much cheaper than I do. Ok, at least I thought so. Suzuki Germany has them substantially reduced.

Also, while the seals and dust rings have the same number for K2 and K6, I am not sure if the same holds true for the repair kit.

[Snapey]

A rattle gun will get it apart Col then you can make a tool to suit.