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I think the seals on my front forks have gone bad. Oil is leaking out the top and dripping down the pipes. Is it possible to fix them by myself and does anyone know how or is it worth the $200 to get them fixed.
 

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First off, might just be some grit in the seal, get a seal-saver or .004" feeler guage, and insert it into the dust seal, past the fork seal and wipe it around a few times. Often this can dislodge what's causing a minor leak. Cheap fix, if not.

If you want to do it yourself, it's really not very hard. Follow the manual, there are numerous youtube videos on traditional forks that will give you an idea of what's involved.

You don't need any special tools really other than a fork-seal driver, and you can make one out of PVC, or Rocky Mountain ATV has the Tusk brand for $30 something.

I'd rate it a 5 out of 10 for difficulty, easy if you've got some basic mechanical skills and decent tools.
 

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Often

Often the seals just have some junk behind the lips. If you clean them out well, they'll often return to proper sealing. The most effective way is to remove the forks and disassemble the fork tubes, which isn't a huge job, especially if you have a centerstand. Before you do, take a flashlight and take a very close look at the fork tubes to be sure there are no chips or dings in them, which will ruin seals in short order. If you find some, and they are minimal, some work with wet-or-dry sandpaper in 400-800 grit may smooth the tubes out enough to work. Didn't say how old your bike was. If more than a couple of years old, probably time to change the fork oil anyway.
 

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If you replace the seals yourself, follow Black Lab's HowTo, AND have all the correct parts on hand, it would probably take a couple of hours to do.

It took me three weeks, but then I had the wrong part - twice. . .
 

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For driving the fork seals, almost anything that is thin and curved and not too hard and can push the seal down will work. People have used a screwdriver covered in tape, I use a paint stirring stick. Just go around and push it in bit by bit, no problem!
 

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For driving the fork seals, almost anything that is thin and curved and not too hard and can push the seal down will work. People have used a screwdriver covered in tape, I use a paint stirring stick. Just go around and push it in bit by bit, no problem!
True, anything will work, but you ever done it with a fork seal driver? Makes it a 2-second job, and you KNOW you're not ****ing it up. I used some pennytech stuff to do it, and I finally broke down and bought one....makes it so easy.
 

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Film negative

First off, might just be some grit in the seal, get a seal-saver or .004" feeler guage, and insert it into the dust seal, past the fork seal and wipe it around a few times. Often this can dislodge what's causing a minor leak. Cheap fix, if not.
Here is an old dirt bike trick:

Use an old negative or piece of film strip to fish out the junk in seal. wrap the film around the fork and rotate it back and forth while pushing it gently past the dust seal and into the fork seal. The holes in the film strip will hold the junk as you pull it back out. Wipe down the fork and film strip and repeat. Cycle the forks in between cleaning and wipe down the forks again.

I just did this on my '03 and it fixed my leak.

If you do r&r the forks you can use a piece of pvc split vertically as a seal driver.

If you use belray waterproof grease between the fork seal and dust seal it will help to keep out the debris.
 

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I think the seals on my front forks have gone bad. Oil is leaking out the top and dripping down the pipes. Is it possible to fix them by myself and does anyone know how or is it worth the $200 to get them fixed.

:thumbup: You can get new OEM Suzuki fork seals and dust covers for both forks, shipped to your door anywhere in the USA, for about $60 all in,

If you would like a set to do the replacements yourself, just let me know and I will get you looked after right away,

Email me at [email protected] rather than PM for faster response,

Enjoy the ride, and best regards,
Blair
 

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Just a comment,
Blair is a great guy to do business with!
If he has the parts you need, but them from him.

No affiliation, just a satisfied customer!
 

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Here is an old dirt bike trick:

Use an old negative or piece of film strip to fish out the junk in seal. wrap the film around the fork and rotate it back and forth while pushing it gently past the dust seal and into the fork seal. The holes in the film strip will hold the junk as you pull it back out. Wipe down the fork and film strip and repeat. Cycle the forks in between cleaning and wipe down the forks again.

I just did this on my '03 and it fixed my leak.

If you do r&r the forks you can use a piece of pvc split vertically as a seal driver.

If you use belray waterproof grease between the fork seal and dust seal it will help to keep out the debris.
Good tip, I've heard of the 35mm trick but I don't think 35mm is easy to find nowadays!

+1 on the waterproof grease between the seals too, do that on my forks too. Another thing that makes service REALLY easy is to soak the new fork seal in fork oil for an hour or so before installing, goes in super easy that way.

The only thing I use the driver for, really, is to smack the bushings down into place (where applicable). But there its invaluable.
 
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