Suzuki GSX-R1000 Fork Seals Replacement
Replacing the fork seals on a Suzuki GSX-R1000 requires the removal of several parts, including the front wheel, the front brake caliper assemblies, the front fender and the forks themselves.
Watch the video above and follow the steps below to replace the front fork seals on a Suzuki GSXR 1000.
Tools and Parts - Suzuki GSX-R1000 Fork Seal Replacement
- Ratchet and extensions
- 4mm, 5mm, 6mm Allens
- 17mm wrench
- Screwdrivers
- Small pry bar
- Pick tool
- Pliers
- Torque wrench
- Fork dust seals (x2)
- Fork oil seals (x2)
- Oil seal circlips (x2)
- Fork O-rings (x2)
- Fork oil
In addition to the regular tools listed above, you're going to need the following specialty tools:
How to Replace Suzuki GSX-R1000 Front Fork Seals
Step 1. Remove the front brake calipers by taking off the pair of 12mm mounting bolts that hold them in place.
Step 2. Remove the front wheel by taking off the 22mm axle bolt from the right side, loosening the four 10mm axle pinch bolts (two on each side) and pulling the axle out from the left side of the wheel.
Step 3. Remove the front fender by taking out the three Allen bolts on each side.
Step 4. Loosen the 24mm fork cap bolts located at the top of the fork tubes by a turn or so without removing them.
Step 5. Loosen the fork clamps by first loosening the 6mm Allen bolts securing them to the forks.
Step 6. Carefully remove the front forks by pulling them down and out of the fork clamps, twisting them as you do so.
NOTE: From this point on we'll be working on a single fork.
Step 7. Unscrew the fork cap bolt from the fork tube.
Step 8. Use the front fork holder tool to hold the spring spacer, and push it downward until you can get the fork spring stopper plate tool over the spacer to lock it in place.
Step 9. Remove the fork cap bolt and the rod beneath it.
Step 10. Hold down the spring spacer with the front fork holder tool to release the pressure on the fork spring stopper plate tool, then remove the stopper plate tool. Next, carefully release the pressure on the front fork holder tool and remove the holder tool.
Step 11. Remove the spring spacer and its washers, then remove the fork spring and drain out the fork oil.
Step 12. Slide the outer fork tube off the inner fork tube and clean them both.
Step 13. Remove the dust seal, oil seal circlip, oil seal and the spacer seal from the outer fork tube. Take note of the direction the seals were facing as you remove them, so you can install the new ones in the correct way.
Step 14. Lightly lube the outside of the inner fork tube, and install the new seals over the fork tube in the order and direction the old ones came off.
Step 15. Slide the inner fork tube back into the outer fork tube, and use the fork seal installer tool to drive the oil seal down into place. Next, install the oil seal circlip and the outer dust seal.
Step 16. Refill the fork with fork oil. Fill the fork to just below the brim, attach the damping rod holder tool to the damper rod, and raise and lower the damper rod about 10 times to remove any air trapped in the fork. Leave the fork to stand for 5 minutes, then raise and lower the damper rod a couple more times and let it sit for another minute.
Step 17. Remove the damping rod holder tool, then reinstall the rod you removed in Step 9 and top off the fork oil until it reaches the top of the outer fork tube.
Step 18. Work the inner fork tube out and back into the outer tube a few times to distribute the oil within the entire damping system. Leave the fork to sit for a couple of minutes.
Step 19. Set a fork oil extractor tool to a level of 124mm, and remove the excess fork oil from the tube.
Step 20. Reattach the damping rod holder, hold the damper rod in place with the fork spring stopper plate tool, and set the height of the screw thread to 11mm.
Step 21. Reinstall the fork spring — making sure the tapered end is facing upwards — and then reinstall the spring spacer and its washers.
Step 22. Use the front fork holder tool to hold the spring spacer and compress it back down.
PRO TIP: Use a ratchet strap looped under the fork to keep the holder tool compressed.
Step 23. Raise the damper rod and hold it in place with the fork spring stopper plate tool. Double-check that the height of the screw thread is still set to 11mm.
Step 24. Remove the old O-ring from the fork cap, install a new O-ring and reinstall the cap onto the fork tube. Torque the fork cap locking nut to 11 foot-pounds.
Step 25. Pull down on the front fork holder tool, remove the fork spring stopper plate tool, carefully lower the damper back down, slowly release the pressure on the fork holder tool and remove the tool.
Step 26. Tighten the fork cap until it's snug, but don't fully tighten the cap yet.
Step 27. Repeat steps 7 through 26 for the other fork.
Step 28. Reinstall the forks into the fork clamps, and set them so there is 10mm between the fork cap and the top of the triple tree.
Step 29. Retighten the fork clamp Allen bolts, then reinstall the front fender, the front wheel and the front brake calipers. Torque the fork cap bolts to 16 foot-pounds and you're done.
