Front fork spring stopper problem. Suzuki GR 650.

[smmi10]

Hi, i'm working on a 1985 Suzuki GR 650 and i want to change fork oil and inspect the spring oil seal. Anyone know how to open the fork? Manual says that i should take out spring stopper by removing clip while pushing down the spring stopper.

Problem is that the fork is missing spring stopper circlip or spring stopper or something. There seems to be an metal cap, possibly spring stopper, on top of the fork (picture 2) that is somehow bolted to the fork and cant be lifted out. So does anyone know how to open the fork for disassembly.

There is a possibility that the forks are from a different bike since i bought the bike this summer and the bike's history is unknown. So if anyone recognises the forks that would help alot.

[Bhud]

If you don't have a bench vice, put the wheels and forks back on the bike. Take a rod or something in one hand, and a small flathead screwdriver in the other. Push down hard on the "spring stopper" using the rod in one hand. Use your body weight. You will see the spring stopper go down a few mm. While it's pressed down, use the screwdriver to pick out the circlip.

If you have a bench vice, use the same method as above without having to put the forks back on the bike.

[Robby]

You need to push down that metal bit in the top of the fork, which will expose the circlip that you need to lever out.

The fun thing is that the bit you need to push down is probably seized, and you need about 5 hands to push it down, lever out the circlip, then let the pressure off the cap slowly.

You can free it off with some penetrating oil, then give it a sharp tap with a hammer and large drift.

There's a reason that manufacturers stopped using that design of fork top cap.

[stinkwheel]

Top tip. If you put it back in the bike, you can use a 2 or 3-leg puller hooked under the edges of the top yoke to compress the fork cap. It even has a dimple in the centre for the bolt of the puller. One it's compressed, you'll be able to lever the circlip out of the groove with a flat bladed screwdriver, it's just a thin circle of wire.

I would advise wearing eye protection because the stopper is under spring pressure, You want to ease tyhe tension off slowly but if the puller slips off once the circlip is removed, it'll fire the stopper out like a bullet.

Remember to loosen the bottom damper rod bolts before removing the cap if it is your intention to strip the fork down.
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.