Suzuki GS550L 1981 forks

[TerminalMan]

I've got a 1981 Suzuki GS550L which I'm trying to bring into reasonable shape. I'm currently working on the forks to replace the seals and fluid - but I've no idea how to get the tops off. They usually have hex ends on them, but these ones are blank. They just had rubber caps over the top of them, with these blank ends underneath. Any ideas?

Cheers,
Al

[Raffles]

You need to depress the endcap (the round thing with a dimple in it in your picture) and remove the circlip in order to release the cap.
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A good loser will always be a loser.

[TerminalMan]

Thanks - I'll give that a go.

[stinkwheel]

Easiest way is to clamp it back in the yokes then use a two or three leg puller hooked under the top yoke to push the cap down and hold it there (I'm pretty sure that's why there is a dimple in the centre of them), then you can pry the circlip out and release the spring tension slowly and in a controlled fashion.

Nobody likes being hit in the face with a ballistic lump of metal which is what will happen if you try to do it by pushing down and getting someone to ping the circlip out. They are a near impossability to put back in if they aren't clamped in something.
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“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.

[Pete.]

I can't remember if the 550 was the same but for sure on the 850 once you get the spring out you need to undo the bolt in the bottom of the fork leg to dismantle the rest of it, but the inside piece (damper?) will spin. To stop it from turning you put 2 M12 nuts on a long bit of studding and poke it down the leg do engage with the cutout in the damper then the bolt will un-do.
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[TerminalMan]

Top tips - thanks.

I've actually gone about this somewhat arse-about-face; The forks aren't on the bike at the moment, so I've already removed the bolt from the bottom of both forks and drained them. One of the stanchions is out; the other is being a bit more difficult.

I'm tempted to replace the seals and reassemble them, then try refilling the oil from the holes at the bottom before replacing the bolts - saving myself from messing about with the caps. Might this work?

[Bhud]

Others will have found it difficult as well, which could mean that the forks are long overdue a complete overhaul. Do you have a spare helmet? Maybe try putting the helmet on, closing the visor, then with the forks back on the bike (empty of oil), and the front wheel as well, pushing down on the depression in the cap with a long tool (maybe a socket extender) in one hand, then with a small flathead screwdriver in the other hand, plucking out the circlip. It may fire into your face, so don't do this and wear a helmet if you do. Yeah but no but, etc.

[Pete.]

Jubilee-clip a ring spanner to the leg with the ring end up above the top edge. Use an open-ended spanner and long socket to depress the plug by hooking the spanner into the ring spanner end and using it as a lever. Once you have the plug depressed, pick out the spring clip.
____________________
a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good