fork oil leak

RonWhitm · 08-30-2007, 01:40 PM

Hi folks, haven't posted in a while but need some advice now. I recently noticed one of my fork tubes is leaking oil. I checked out the manual and I suspect this repair is not a project I want to mess with, for several reasons. Has anyone here ever disassembled and reassembled their forks to change oil, seals, etc.? It looks like a special tools and equipment project and might best be left to the pros. Any ideas on the approximate cost if I take it to a shop?
Any and all comments appreciated.
Ron

Water Warrior 2 · 08-30-2007, 07:03 PM

Just my opinion. Take the forks to some one who does it for a living. Once took forks to a dealer and had new seals installed. Put the forks back on the bike and happily road away.

Badbob · 09-01-2007, 11:59 AM

I've never done this myself. Never had to. However, my daughter does hers and they are bit more complicated that a GZ250.

RonWhitm · 10-05-2007, 03:53 PM

I stopped in at the nearest Suzuki service dealer today to inquire about my fork issue. They were somewhat helpful and encouraging. I could tell they don't deal much with little bikes however. The man I spoke with looked at the bike and was surprised there was no drain plug for the fork oil. He did mention he had seen much worse that were still on the road. BTW if anyone is interested, the going rate for labor at that shop in League City, TX is $75/hr + parts, etc. Makes me want to rethink doing it myself. I did get some good free advice though.

xt477 · 10-06-2007, 11:25 AM

" I did get some good free advice though"

Like?

johncruise · 10-06-2007, 03:04 PM

Quote:

Originally Posted by RonWhitm

BTW if anyone is interested, the going rate for labor at that shop in League City, TX is $75/hr + parts, etc. Makes me want to rethink doing it myself. I did get some good free advice though.

Still cheaper there. Down here in Sunnyvale/Santa Clara California... it's around $85+ (GP Sport, Bike World, and Santa Clara Cycle).

RonWhitm · 10-08-2007, 10:46 AM

The free advice, not much really, was that adding small amounts of oil to replace what was lost could delay my having to pull the fork and do a major overhaul. I was also told that as long as I didn't notice any uneven travel in the suspension, the dampers were still working and no damage has occurred. I bought a heavier oil to use, hoping the leak will stop or slow done, until I can do a proper repair.

anjames · 09-25-2010, 03:00 PM

I have the same problem with a GZ250 I've been nursing back to running condition, and bought new fork seals and wipers to replace the old ones.

There is also a small copper gasket at the bottom bolt which I'll have to pick up, but the really frustrating thing just now is that there is some sort of special tool which I don't think the service manual mentions for the step 'Remove the inner tube from the outer tube'. It looks like there's some sort of locking piece at the bottom of the tube which needs to be removed before you can separate the inner and outer tubes... or maybe I'm just being a sissy and need to muscle them apart... but I'm not really in the mood to buy new forks if I destroy the old ones so I was wondering if anyone has experience with this bit?

anjames · 09-25-2010, 03:08 PM

Nevermind. No special parts needed, just some caveman action. You basically have to sort of ram the inner and outer tubes apart numerous times which gradually will work out the fork seal, then the whole thing will separate easily. Der.

spicciani · 12-30-2010, 12:24 PM

I have replaced the seals and oil on ninja 250 forks it was a trip but really its not that hard. The the problems i ran into is that im weak and you had to pull them apart pretty hard , but it came apart . and i had to buy pvc pipe to use in place of the special tool to get the fork seals back in.

is crapy seals pretty common on the gz250 i just bought one yesterday and it looks like the need to be replaced

08-30-2007, 01:40 PM	#1
RonWhitm Member Join Date: Apr 2007 Location: Galveston, Texas Posts: 51	fork oil leak Hi folks, haven't posted in a while but need some advice now. I recently noticed one of my fork tubes is leaking oil. I checked out the manual and I suspect this repair is not a project I want to mess with, for several reasons. Has anyone here ever disassembled and reassembled their forks to change oil, seals, etc.? It looks like a special tools and equipment project and might best be left to the pros. Any ideas on the approximate cost if I take it to a shop? Any and all comments appreciated. Ron __________________ Ron Whitmore FSSNOC #4914 2005 GZ250 2004 Tomos LX Login or Register to Remove Ads
	0

09-01-2007, 11:59 AM	#3
Badbob Senior Member Join Date: Aug 2006 Location: Tallahassee FL Posts: 945	I've never done this myself. Never had to. However, my daughter does hers and they are bit more complicated that a GZ250. __________________ My GZ250 Blog Facebook Pinterest Google+ Tumblr YouTube Lumber Jocks Login or Register to Remove Ads
	0

10-05-2007, 03:53 PM	#4
RonWhitm Member Join Date: Apr 2007 Location: Galveston, Texas Posts: 51	I stopped in at the nearest Suzuki service dealer today to inquire about my fork issue. They were somewhat helpful and encouraging. I could tell they don't deal much with little bikes however. The man I spoke with looked at the bike and was surprised there was no drain plug for the fork oil. He did mention he had seen much worse that were still on the road. BTW if anyone is interested, the going rate for labor at that shop in League City, TX is $75/hr + parts, etc. Makes me want to rethink doing it myself. I did get some good free advice though. __________________ Ron Whitmore FSSNOC #4914 2005 GZ250 2004 Tomos LX
	0

10-06-2007, 11:25 AM	#5
xt477 Member Join Date: May 2007 Location: Columbus Ohio Posts: 41	" I did get some good free advice though" Like? Login or Register to Remove Ads
	0

10-08-2007, 10:46 AM	#7
RonWhitm Member Join Date: Apr 2007 Location: Galveston, Texas Posts: 51	The free advice, not much really, was that adding small amounts of oil to replace what was lost could delay my having to pull the fork and do a major overhaul. I was also told that as long as I didn't notice any uneven travel in the suspension, the dampers were still working and no damage has occurred. I bought a heavier oil to use, hoping the leak will stop or slow done, until I can do a proper repair. __________________ Ron Whitmore FSSNOC #4914 2005 GZ250 2004 Tomos LX
	0

08-30-2007, 07:03 PM	#2
Water Warrior 2 Senior Member Join Date: Dec 2006 Location: Squamish B.C Canada Posts: 11,409	Just my opinion. Take the forks to some one who does it for a living. Once took forks to a dealer and had new seals installed. Put the forks back on the bike and happily road away.
	0

09-25-2010, 03:00 PM	#8
anjames Junior Member Join Date: Sep 2010 Location: San Diego, CA Posts: 12	Re: fork oil leak I have the same problem with a GZ250 I've been nursing back to running condition, and bought new fork seals and wipers to replace the old ones. There is also a small copper gasket at the bottom bolt which I'll have to pick up, but the really frustrating thing just now is that there is some sort of special tool which I don't think the service manual mentions for the step 'Remove the inner tube from the outer tube'. It looks like there's some sort of locking piece at the bottom of the tube which needs to be removed before you can separate the inner and outer tubes... or maybe I'm just being a sissy and need to muscle them apart... but I'm not really in the mood to buy new forks if I destroy the old ones so I was wondering if anyone has experience with this bit?
	0

09-25-2010, 03:08 PM	#9
anjames Junior Member Join Date: Sep 2010 Location: San Diego, CA Posts: 12	Re: fork oil leak Nevermind. No special parts needed, just some caveman action. You basically have to sort of ram the inner and outer tubes apart numerous times which gradually will work out the fork seal, then the whole thing will separate easily. Der.
	0

12-30-2010, 12:24 PM	#10
spicciani Member Join Date: Dec 2010 Location: Mobile, Alabama Posts: 70	Re: fork oil leak I have replaced the seals and oil on ninja 250 forks it was a trip but really its not that hard. The the problems i ran into is that im weak and you had to pull them apart pretty hard , but it came apart . and i had to buy pvc pipe to use in place of the special tool to get the fork seals back in. is crapy seals pretty common on the gz250 i just bought one yesterday and it looks like the need to be replaced
	0