Stuck replacing fork seal - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
DL1000 from 2002-2012 DL1000 from 2002-2012 (K2-L2)

 
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post #1 of 4 Old 06-23-2019, 12:03 AM Thread Starter
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Join Date: Jan 2018
Location: Mesa, Az
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Stuck replacing fork seal

Hi,
Replacing fork seals on my 05 DL1000. Started w/the right side, the leaky side and that went easy-peasy.

I figured I should do both, so I took apart the left side to replace it today. Everything came apart OK, but when I went to reinstall the inner fork into the outer fork, I realized there wasn't enough room to get the new seal in so I could install the metal O-Ring above the oil seal.

So I pulled the inner fork out of the outer and noticed that the slide bush wasn't seating into the lower fork - not one bit. I even bought a new one with the new seals just in case, but the new one won't slide in at all into the lower fork.

When I first bought my DL last year I remember someone posted something about how to fix this but I can't find it.

I guess I got really lucky on the first fork because everything just slid in and all I had to really worry about was setting the oil seal properly.

Has anyone gone though this and if so how did you slide that thang in !

TIA

05 DL1000

Past Bikes:

05 Z750S
94 KLR650
95 KLR650
05 ZG1000
92 ST1100
03 F650GS
03 ZR-7S
82 Sabre 750
98 KLR250
82 KZ750LTD
82 KZ550LTD
74 TC125
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post #2 of 4 Old 06-23-2019, 05:03 AM
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Location: South Africa
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Maybe the video on the Wee may be of help to you https://www.stromtrooper.com/dl650-d...ork-seals.html. Have you googled "DL1000 fork seal replacement + video"?
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post #3 of 4 Old 06-23-2019, 03:14 PM
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Join Date: Jun 2019
Location: Brookfield
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Google black lab fork-seal replacement as well. Really good write up and picture. My dust covers are cracked but no leaking so far. Id probably install heavier springs when I do it, I get a lot of break dive.
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post #4 of 4 Old 06-23-2019, 03:28 PM Thread Starter
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Join Date: Jan 2018
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Posts: 13
Thanks! I think the black lab site was the one I saw last year but forgot to bookmark. I appreciate all of your responses! I ended up just using the PVC (split so it'd fit) to push down the bushing - with the big washer on top of the bushing. I'll be glad to have this done! New Metzler front tire, new front pads because the fork oil leaked onto the right pads. After this I'm going to have to take the tank off since it looks like I have a slight coolant leak on the top of the engine. I see a tried 'trail' of what I'm pretty sure is coolant, but it's not a fast leak.

Thanks again for the help.

05 DL1000

Past Bikes:

05 Z750S
94 KLR650
95 KLR650
05 ZG1000
92 ST1100
03 F650GS
03 ZR-7S
82 Sabre 750
98 KLR250
82 KZ750LTD
82 KZ550LTD
74 TC125
jwtacoma is offline  
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