11 Fork Maintenance - Stromtrooper Forum : Suzuki V-Strom Motorcycle Forums
DL650 and DL650A - 2004 to 2011 DL650 from 2004-2006 (K4-K6) and DL650 or DL650A from 2007-2011 (K7-L1)

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post #1 of 13 Old 04-17-2019, 12:45 PM Thread Starter
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11 Fork Maintenance

Finally realizing that the forks are leaking, mostly the right side it seems, I am going to order new dust and oil seals along with 2 slide metal parts. Aside from the fork oil I would like to know what more I may need. I changed the fork oil at 30,000 miles by removing and inverting the tubes, and at the time I re-assembled them, but I did not replace any seals, etc. At any rate I will report back when job is complete.

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post #2 of 13 Old 04-17-2019, 01:39 PM
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I did it last year on my sons gen-1 650 and can't really remember what special tools I needed or used other than a plastic device designed to slip the new seals over the tubes without doing damage to them.

Black Lab has the best step by step instruction to help you with what you need and how to get it done. If I can find the link I'll come back here and add it to this post.

Here you go... https://blacklabadventures.com/2012/...nt-fork-seals/
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Last edited by gdrew; 04-17-2019 at 01:49 PM.
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post #3 of 13 Old 04-19-2019, 11:28 AM
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Originally Posted by frankintx View Post
Finally realizing that the forks are leaking, mostly the right side it seems, I am going to order new dust and oil seals along with 2 slide metal parts. Aside from the fork oil I would like to know what more I may need. I changed the fork oil at 30,000 miles by removing and inverting the tubes, and at the time I re-assembled them, but I did not replace any seals, etc. At any rate I will report back when job is complete.
As a hindsight dust actually causes most fork seal leaks. If you disassemble the fork but don't replace seals you should clean the seals and dust covers.

Just an FYI
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post #4 of 13 Old 04-19-2019, 11:39 AM
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When I rebulid forks I replace the dust seal, oil seal, fork cap o-ring, upper and lower bushings, and the small copper sealing ring on the bolt in the bottom of the lower stanchion.
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post #5 of 13 Old 04-20-2019, 06:32 AM
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Also check that the fork inner tube (item #10-34 in https://www.ronayers.com/oemparts/a/...a/front-damper) is free of rust spots / insects / pitting / etc. A damaged inner tube will soon reproduce the fork seal leak. One of the reasons some riders make use of fork gaiters (https://www.stromtrooper.com/general...x-similar.html).
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post #6 of 13 Old 04-20-2019, 02:41 PM
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If you want to prevent future wear and trouble consider adding gaiters:

https://www.google.com/search?ei=TFm...10.7tVVzixjN-M

I use removable neoprene ones but once you have the fork tubes out you may as well use rubber booty ones.
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post #7 of 13 Old 04-24-2019, 04:34 AM
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All great advice here. I'm going to go down the gaiters route when I have time to drop the forks out for an oil change and I also like to replace more than just the seals; both bushes, dust seals and copper washer are all a good idea.

You may already have all the tools you need but I have never used a seal driver to drive the seals or the bush as the drivers tend to be expensive and I've had a fair few bikes all with differing fork diameters.

I've always done it using electrical tape. Never had an issue. Works on all diameters as well. Look on Youtube for a quick guide.

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post #8 of 13 Old 05-05-2019, 02:20 PM Thread Starter
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Thanks for the info fellow strommers. I have taken apart the left fork, but in trying to assemble the fork I probably ruined the lower part. I believe the guide metal part that I tried to re-use did not go where I tried to install it. I have not seen anyone else with this problem so I assume I screwed up the job by trying to force the guide metal into the recess on the lower fork.

So now the guide metal "sleeve" is stuck in the lower fork. It is not fully seated, but it is warped and the inner fork does not slide in. Since I now have to buy or find another lower I may pound it in, but that probably won't work. Taking it out will almost certainly ruin the lower unless a shop can do it. Will have to think about for awhile.
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post #9 of 13 Old 05-05-2019, 06:55 PM Thread Starter
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I will take apart the right fork and see what happens. I don't know what happened with the left side, but it will probably be the same on the right. No telling what I will do then.
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post #10 of 13 Old 05-05-2019, 07:43 PM
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Originally Posted by frankintx View Post
Thanks for the info fellow strommers. I have taken apart the left fork, but in trying to assemble the fork I probably ruined the lower part. I believe the guide metal part that I tried to re-use did not go where I tried to install it. I have not seen anyone else with this problem so I assume I screwed up the job by trying to force the guide metal into the recess on the lower fork.

So now the guide metal "sleeve" is stuck in the lower fork. It is not fully seated, but it is warped and the inner fork does not slide in. Since I now have to buy or find another lower I may pound it in, but that probably won't work. Taking it out will almost certainly ruin the lower unless a shop can do it. Will have to think about for awhile.
Hmmm....I slide the inner fork tube (with the bushing on the bottom installed) into the lower leg then slide the guide metal bushing over the tube followed by the spacer (washer) and tap it in using PVC pipe. It sounds like you may have installed the guide metal bushing before dropping the tube into the lower leg. If so, fork won't slide in with it's bushing installed. I did this job last week, one guide bushing went in easily, the other fought me. It's not unusual for them to sometimes be a little tough to seat.

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