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Old 03-28-2013, 03:47 PM   #436
sp600
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Joined: May 2012
Location: Chicaga
Oddometer: 59
Fork Oil Seal Change

Hi guys!

Unfortunately one of my fork seals is leaking oil. Since one is leaking I'm just going to buy a pair of new seals and do both forks while I'm at it. I got as far as draining the old oil out and removing the spring, spring spacer, washer, and cap nut. However, I can't figure out how to remove the deeper internals like the damper rod. I've tried sharpening an old broomstick and jamming it in to lock up the damper rod and prevent spinning but it didn't work. Any other suggestions?

http://www.alpha-sports.com/tools/suzuki_tools.htm If I buy the fork tool from here (about half way down 09940-34520), does anybody know which attachment I need?
Thanks!
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Old 03-29-2013, 09:15 PM   #437
RiderRat
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Location: Philadelphia
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Front Wheel???????

- SP600,
Sorry I don't have any advice for you... The repair manual doesn't offer too much help either.

My question for the group is... Anyone else experience extreme difficult taking the front wheel off?

I was able to take the cotter pin out and the nut on the right side off but the left side ( disc side ) will not budge, at all. I'm afraid to chew up the head of the bolt too much. Any ideas??? I'm got about one can of PB Blaster sprayed on it so far

Thanks much
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Old 03-30-2013, 12:36 PM   #438
sp600
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Take out the axle? and you should be good. If you have the cotter pin out and the crown nut off, which should have been on the left side of the bike (rotor side), then all you have to do is take out the axle because the "nut" on the other end is welded to the axle. Should take about 5 mins. to get the front wheel off.

Edit: If the axle seems stuck just hit the end with a rubber mallet.
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Old 03-30-2013, 12:46 PM   #439
RiderRat
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Quote:
Originally Posted by sp600 View Post
Take out the axle? and you should be good. If you have the cotter pin out and the crown nut off, which should have been on the left side of the bike (rotor side), then all you have to do is take out the axle because the "nut" on the other end is welded to the axle. Should take about 5 mins. to get the front wheel off.

Edit: If the axle seems stuck just hit the end with a rubber mallet.
Thanks... I have taken many front wheels off dirt bikes (I'm not a total noob lol) but this one won't budge! My father and I were trying for a while. Is the axle threaded on the opposite side of the crown nut, it wont turn out or budge even with some mallet love. It seems totally stuck, I was even riding it around with the crown nut off trying to get the vibrations to loosen it.. ( I know, stupid)

Could my axle be seized? Completely??
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Old 03-30-2013, 02:45 PM   #440
sp600
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After the crown nut side, the axle is completely smooth. Sorry I'm not too helpful. You could try heating it with a blow torch... It must really be stuck.
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Old 03-30-2013, 03:52 PM   #441
RiderRat
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Quote:
Originally Posted by sp600 View Post
After the crown nut side, the axle is completely smooth. Sorry I'm not too helpful. You could try heating it with a blow torch... It must really be stuck.
Nope, very helpful, exactly what I needed to know. Wasn't sure if it was totally smooth or not. A blow torch and some more tapping and hopefully that should do the trick!

Thanks again, I'll keep ya'll posted
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Old 04-01-2013, 09:02 PM   #442
RiderRat
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New brakes!

Sorry for all the hype over getting the axle out! With a little heat and a larger hammer got the wheel off pretty easily

After the wheel came off the new disc went on and then I took the bike to my family's foundry and got to work! The pics below are of the 1990 caliper on the vice with a new piece of steel to make up the gap from the new caliper. There's a pic of the caliper mounted and one of the before/after of the disc.
[IMG][/IMG]


[IMG][/IMG]

(sorry using a poor image host, turn your head)
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Old 04-02-2013, 11:03 PM   #443
sp600
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Nice job!

I like the last pic, you can really see a difference in size. Which parts did you end up using exactly? I noticed the dual caliper piston and steel braided brake lines.
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Old 04-10-2013, 10:29 PM   #444
RiderRat
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Quote:
Originally Posted by sp600 View Post
I like the last pic, you can really see a difference in size. Which parts did you end up using exactly? I noticed the dual caliper piston and steel braided brake lines.
Hey!
I used a 1990 DR650 disc and caliper that I found on ebay for a steal and with a little modification it bolted up nicely. The steel braided line was a random from my local parts store that he cut me a deal on, I'll try to look for a marking. I also have a random master-cylinder from what I think is a CRF 250 possibly?? I'm going to try to link them together and hopefully they link-up well.

I'll keep you guys posted!!
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Old 04-19-2013, 06:18 PM   #445
sp600
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Finally got around to fixing my petcock

http://s834.photobucket.com/user/acw...tml?sort=3&o=0

Didn't turn out too bad.
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Old 04-20-2013, 07:35 AM   #446
brucifer
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Quote:
Originally Posted by sp600 View Post
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Old 04-20-2013, 11:58 PM   #447
RiderRat
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Originally Posted by brucifer View Post
[URL="http://s834.photobucket.com/user/acwagner13/media/SDC10212.jpg.html"]
What tank is that from? Is this on an SP??
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Old 04-24-2013, 04:38 PM   #448
sp600
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Plastic Tank

The tank is a 3.5-4 gallon oversize universal plastic tank. The holes are the same width as the oem petcock though. Here's a link: http://northcoastmotorsports.com/pro...roducts_id=772


BTW Does anyone have a spare set of front/ rear hubs that they would be willing to part with? I'm thinking about picking up some supermoto style rims and don't want to sacrifice the ability to switch between street and dirt tires.
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Old 05-16-2013, 02:58 AM   #449
sp600
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Pissed

I want to ride so badly.
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Old 05-16-2013, 03:54 PM   #450
stussels
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whats the hold up?
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